Waveguide Refractive Index Profile via Selective Curing and Intermixing

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Solution Overview

Problem

Conventional methods for preparing waveguides require etching steps to remove uncured core layer portions, which are costly and time-consuming, and result in an undesirable refractive index profile if not fully removed.

Innovation Solution

A method involving selective curing of a first composition on a substrate to form a contrast layer with both cured and uncured portions, followed by applying a second composition to intermix with the uncured portions, creating an intermixed portion with a distinct refractive index, eliminating the need for etching and reducing fabrication steps and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If etching steps are used to remove uncured core layer portions, then the refractive index profile is improved, but the manufacturing cost and time increase significantly

Engineering Contradiction:
Improverefractive index profileVSAvoidfabrication time
Core Design Contradiction:
Manufacturing precisionVSProductivity

Solution Approach 1:

The patent extracts the harmful uncured portions of the core layer through selective curing processes, allowing the uncured material to be removed without requiring additional etching steps. This is achieved by controlling the curing process to leave specific portions uncured, which are then naturally removed, eliminating the need for time-consuming etching while maintaining the desired refractive index profile.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the curing parameters (such as curing depth, intensity, or pattern) to create a gradient or selective curing effect in the core layer. This allows different portions of the core layer to have different degrees of curing, enabling the uncured portions to be selectively removed while preserving the cured portions, thus achieving the desired refractive index profile without additional etching steps.

Inventive Principle:
Principle #35Parameter changes

2Manufacturing precision

If etching steps are used to remove uncured core layer portions, then the refractive index profile is improved, but the manufacturing cost increases

Engineering Contradiction:
Improverefractive index profileVSAvoidmanufacturing cost
Core Design Contradiction:
Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent extracts the harmful uncured portions of the core layer through selective curing processes, allowing the uncured material to be removed without requiring additional etching steps. This eliminates the need for expensive etching chemicals and equipment while maintaining the desired refractive index profile.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs a self-service mechanism where the uncured portions of the core layer are naturally removed through the curing process itself or subsequent simple cleaning steps, rather than requiring additional active etching operations. This reduces manufacturing complexity and cost while achieving the desired refractive index profile.

Inventive Principle:
Principle #25Self-service

3Device complexity

If uncured portions are not completely removed, then the fabrication process is simplified, but the refractive index profile becomes undesirable

Engineering Contradiction:
Improvefabrication stepsVSAvoidrefractive index profile
Core Design Contradiction:
Device complexityVSManufacturing precision

Solution Approach 1:

The patent applies local quality by creating different curing states in different portions of the core layer. The selective curing process ensures that specific regions are fully cured while other regions remain uncured or partially cured, allowing for controlled removal of uncured portions. This local differentiation enables the achievement of the desired refractive index profile through simplified fabrication steps.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent changes the curing parameters spatially across the core layer to create a gradient or patterned curing effect. By controlling parameters such as curing intensity, duration, or wavelength distribution, the process creates regions with different refractive indices and curing states, enabling the uncured portions to be selectively removed while maintaining the desired overall refractive index profile.

Inventive Principle:
Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method produces waveguides with excellent optical and physical properties at a lower cost and with fewer steps, achieving a desirable refractive index profile without the need for complete physical removal of uncured portions.

Implementation Method 1

selective curing of a first composition on a substrate to form a contrast layer with both cured and uncured portions

Methodology Applied
Scientific EffectPhotopolymerization: Photopolymerisation

Implementation Method 2

applying a second composition to intermix with the uncured portions, creating an intermixed portion with a distinct refractive index

Methodology Applied
Scientific EffectDiffusion: Diffusion

Data Source

PatentEP2996867B1Method of preparing an article and article prepared thereby
Publication Date: 2018.09.19 DOW SILICONES CORP
  • EP2996867B1 patent drawingFigure 1~2

AI summary

A method of preparing an article comprises applying a first composition having a first refractive index Rl1 on a substrate to form a first layer (14). The method further comprises applying a curing condition to a target portion (18) of the first layer, without applying the curing condition to a non-target portion (16), to form a contrast layer including at least one cured portion and at least one uncured portion. In addition, the method comprises applying a second composition having a second refractive index Rl2 on the contrast layer to form a second layer, wherein a portion of the second layer and the at least one uncured portion of the contrast layer intermix to form at least one intermixed portion having a third refractive index Rl3. Rl1, Rl2, and Rl3 are different from one another