ACTIVE ALIGNMENT OP FIBER AND OPTICAL MODUL
The present invention relates to a technique for actively aligning an optic fibre with an optical element defined in an optic chip, for which a relatively high degree of precision is required.
The technique of active alignment involves adjusting the alignment of an optic fibre with respect to an optic element whilst transmitting light between the optic element and the optic fibre, and fixing the position of the optic fibre on the basis of measurements of the degree of optical coupling as the alignment of the fibre is adjusted.
With optic chips, a relatively high degree of precision is required, and it is an aim of the present invention to provide a new improved active alignment technique for use with optic chips.
The present invention provides a method of actively aligning an optic fibre with an optic element defined in an optic chip supported on a carrier, wherein the active alignment process is carried out with the fibre held in molten glass on the carrier, and the glass is solidified at the end of the active alignment process to fix the fibre in the desired alignment with respect to the optic element.
According to one embodiment of the invention there is provided a method of optically coupling an optic fibre to an optic element defined in an optic chip, the method including the steps of: (a) providing the optic chip on a carrier, (b) holding the fibre in
molten glass on the carrier in an alignment in which light can be transmitted between the optic fibre and the optic element; (c) moving the fibre in the molten glass so as to adjust the alignment of the optic fibre with the optic element whilst transmitting light between the optic element and the optic fibre, and making measurements of the degree of optical coupling between the fibre and optic element as the fibre is so moved; and (d) solidifying the glass with the optic fibre in an alignment selected on the basis of said measurements.
In one. embodiment, the optic chip is a laser chip. However, the technique of the present invention is also applicable to the coupling of optic fibres to other types of optic chips such as those including passive elements such as an optical waveguide leading to a plurality of photodiodes via, for example, a wavelength dispersive elements such as an array waveguide grating (AWG).
According to another embodiment of the present invention, there is provided a method of optically coupling an optic fibre to a light-emitting device defined in an optic chip, the method including the steps of: (a) providing the optic chip on a carrier, (b) holding the fibre in molten glass on the carrier in an alignment in which light can be transmitted between the light-emitting device and the optic fibre; (c) moving the fibre in the molten glass so as to adjust the alignment of the optic fibre with the light- emitting device whilst operating the light-emitting device to transmit light between
optical coupling between the light-emitting device and the fibre as the fibre is so moved; and (d) solidifying the glass with the optic fibre in an alignment selected on the basis of said measurements; wherein the alignment of the optic fibre at the time of
solidifying is selected taking into account the temperature to which the light-emitting device is. exposed during its operation in step (c).
Whilst glass is known as a hermetic sealant, the inventors have found that it is also good for fixing and maintaining the alignment of an optic fibre to a relatively high degree of precision in an active alignment technique. It has been observed that the small movement upon freezing is relatively consistent and reproducible compared to that of solder, which small and reproducible movement is good for achieving good optical coupling between the optic chip and the fibre without the need for multiple re- freezes. Also, it has been observed that glass does not suffer from long term "creep" effect, whereby large changes in optical coupling efficiency over time can be avoided.
The alignment technique of the present invention is useful for example for coupling the output of a laser chip, particularly a single mode output, with an optic fibre, particularly single mode optic fibre.
In the embodiment described below, the optic fibre is aligned for receiving light from a side edge of the optic chip (i.e. an edge where the chip has been diced from a wafer during its production), which side edge may have been polished or otherwise finished to improve the coupling efficiency. The optic fibre thus receives light propagated in a direction perpendicular to the direction in which the layers of the optic chip are
deposited~on-a~substrate_duringrpr^^^ diced.
The alignment technique of the present invention is particularly useful, for example, for cases where the alignment is carried out to sub-micron precision, such as when the optic chip and the optic fibre are of a type wherein a 0.5dB coupling loss results from a deviation as little as 0.3 microns or less.
In one embodiment, the carrier is housed in a package, and a hermetic seal is provided between the fibre and the package at the fibre entry point so as to provide a hermetically sealed environment for the carrier/optic chip.
The present invention also provides a carrier for an optic chip, wherein the carrier is made of a material having a thermal conductivity no less than that of aluminium nitride.
The present invention also provides a carrier for mounting an optic chip on a first portion of a first surface thereof and including a heater at a second portion of said first surface for melting a material used to fix a fibre in a position aligned with the output of the optic chip, wherein the carrier defines slots for controlling the transfer of heat generated by the heater to the optic chip; the slots including a first slot extending downwards from said first surface and dividing said first and second portions of the first surface, and a second slot below the heater.
The-slots~are-o cupied~by~a"^aOuum carrier/optic chip is housed or by another material of relatively low thermal conductivity compared to the carrier material.
The present invention also provides a combination of a carrier as described above with an optic chip mounted thereon.
An embodiment of the present invention is described hereunder, by way of example only, with reference to the accompanying drawings, in which:
Figure 1 shows an optic chip/carrier assembly for use in an embodiment of the technique of the present invention;
Figure 2 shows a glass pre-form for use in an embodiment of the technique of the present invention;
Figure 3 shows the carrier of Figure 1 with an optic fibre held in molten glass on the carrier according to an embodiment of the technique of the present invention;
Figure 4 shows a cross-sectional view of an optic fibre held on the carrier within a solidified glass fillet at the end of an active alignment technique according to an embodiment of the present invention; and
Figure 5 shows a schematic view of the carrier/optic chip in a hermetically sealed housing after the alignment process is completed.
With reference to the accompanying Figures 1 to 4, an optical laser chip 4 is mounted on a carrier 2 made of a material selected for good dissipation of heat away from the laser chip during its normal operation. An example of a suitable material is
the figures. Also not shown in the figures are other components (such as other optical components and temperature control means) that are used dirring normal operation of the laser chip but are not used in the active alignment procedure.
The end length of an optic fibre 12 stripped of its protective claddings is placed on the carrier with its end roughly aligned with the end of the laser chip, and an arch-shaped (horseshoe-shaped) low temperature melting glass pre-form 14a is positioned on the carrier over the optic fibre 12 at a location (area marked 18 in Figure 1) slightly spaced from the end of the laser chip by a vertical slot 6 cut into the carrier 2. The shape of the glass pre-form 14a is selected such that when appropriately heated it collapses over the fibre forming a well-shaped fillet to attach the fibre to the carrier. The glass pre-form 14a is controllably melted by heat provided through the carrier 2 from a resistive heater strip 10 (the associated circuitry is not shown in the figures) provided on a portion of the surface of the carrier 2 adjacent to where the glass preform 14a is located. Positioning the glass pre-form 14a on a portion of the carrier adjacent the heater strip such that the glass pre-form is only indirectly heated by the heater strip via the transfer of heat therefrom through the carrier allows better control of the melting of the glass perform 14a. The heater strip may for example be made.of tantalum nitride.
The melted glass pre-form 14a forms a molten glass fillet 14b around the optic fibre within which the optic fibre can be moved. The laser chip is then operated and the power of the light transmitted from the laser through the optic fibre is measured at a light detector 16. The optic fibre is then moved within the molten glass fillet 14b to
optimum alignment of the end of the optic fibre relative to the laser chip is determined on the basis of the power levels measured at the light detector as the alignment of the end of the optic fibre is adjusted. The molten glass fillet 14b is then cooled and
solidified after first incorporating an offset into the alignment of the optic fibre within the molten glass fillet to take into account (a) the unavoidable movement of the fibre accompanying the solidification of the glass fillet and also (b) the fact that the laser is operated during the alignment procedure at a temperature higlier than that of normal operation as a result of the relatively large amount of heat (350°C) needed to melt the glass fillet. For a given carrier/chip assembly, the size of the offset is determined experimentally for a given set of repeatedly reproducible process conditions.
As mentioned above, a thermally conductive material is selected for the carrier with a view to dissipating heat away from the laser chip during its normal operation. In order to control the amount of heat transferred from the heater strip to the laser chip during the active alignment ' procedure, a vertical slot 6 is formed in the carrier between the portion of the carrier on which the laser chip is located and the portion of the chip on. which the glass fillet and heater strip are located. A horizontal slot 8 is- formed in a portion of the carrier underlying the heater strip 10 for the primary purpose of reducing the transfer of heat from the heater strip through the base of the structure and avoiding excess heating of any elements in that path, such as solder joints, and a thermoelectric cooler if such is provided for use during normal operation of the laser chip. The horizontal slot is also effective in improving the efficiency of the heater strip at heating the glass pre-form and hence reducing the heater current required to melt the glass perform.. This is good for heater strip reliability.
The above-described technique is applicable to any type of optic fibre, including cylindrically-lensed fibres.
Figure 5 shows the carrier/optic chip housed in a hermetically sealed package 19 after the alignment process is completed. The package includes a base 21 and a lid 20,. and a hermetic seal 22 is provided between the base and lid, and between the fibre and the base and lid at the point of fibre entry. The package may be closed under vacuum conditions or in an atmosphere of an inert gas to provide a suitable environment for the optic chip. Either way, the slots 6, 8 are thus occupied by a material having a thermal conductivity lower than that of the carrier material.
The applicant draws attention to the fact that the present invention may include any feature or combination of features disclosed herein either implicitly or explicitly or any generalisation thereof, without limitation to the scope of any definitions set out above. In view of the foregoing description it will be evident to a person skilled in the art that various modifications may be made within the scope of the invention. For example, a remote laser could be used instead of the integral heater strip to melt the glass.