Patent ID: 6738538
Filing Date: 2004-05-18
Classification: G02B

Abstract:
A method of constructing optical structures on semiconductor wafers, comprising the steps of:fabricating multiple Optical Switch components on a top wafer; fabricating a waveguide wafer, wherein the waveguide wafer includes an optical waveguide matrix, fiber attachments and holding structures, and control/monitoring electronics, wherein said waveguide matrix has a plurality of cross-points where the waveguides intersect; creating a receptacle to accommodate an Optical Switch component at each cross-point of said waveguide matrix; fabricating an electrical network on said top wafer, such that said electrical network provides power and control signals to said Optical Switch components on the top wafer until the optical switch components are installed on the waveguide wafer; fabricating mechanical structures and actuators on the top wafer, such that said mechanical structures and actuators may be used to assist with installation of said Optical Switch components on the waveguide wafer; fabricating a set of mating structures on said top wafer and said waveguide wafer, such that each wafer's mating structure is coupled with an opposing structure on the other wafer when the two wafers are brought together; aligning said wafers with each other by using the mating structures; bringing said top wafer and said waveguide wafer together until the mating structures on the top wafer make mechanical and electrical contact with the mating structures on the waveguide wafer, such that each Optical Switch component on said top wafer is precisely positioned at each cross-point of the waveguide matrix on the waveguide wafer; installing the optical switch components onto the waveguide wafer to form electrical and mechanical connections from the waveguide wafer to the respective Optical Switch component at each site in the waveguide matrix; detaching the top wafer from the waveguide wafer, once each Optical Switch component is properly attached to the waveguide wafer; removing the top wafer and leaving behind the installed Optical Switch components on the waveguide wafer.