ELECTRONIC MODULE AND OPTICAL DEVICE

The present disclosure provides an electronic module includes a light source configured to radiate a first light beam having a first wavelength and a converting device configured to receive the first light beam and to convert the first light beam to a second light beam having a second wavelength different from the first wavelength. The electronic module also includes a connection element configured to transmit the first light beam from the light source to the converting device and adapted to a predetermined geometric relationship between the light source and the converting device to meet a condition of total internal reflection.

BACKGROUND

1. Technical Field

The present disclosure generally relates to an electronic module and an optical device.

2. Description of the Related Art

Silicon photonics is a technology that is being researched and developed worldwide, due to its promise of delivering high performance optical devices built using low-cost silicon chip technologies. Providing a sensor hub having optical devices integrated on a silicon base or similar material is desirable.

SUMMARY

In some arrangements, an electronic module includes a light source configured to radiate a first light beam having a first wavelength and a converting device configured to receive the first light beam and to convert the first light beam to a second light beam having a second wavelength different from the first wavelength. The electronic module also includes a connection element configured to transmit the first light beam from the light source to the converting device and adapted to a predetermined geometric relationship between the light source and the converting device to meet a condition of total internal reflection.

In some arrangements, an optical device includes an optical routing structure configured to receive a light from a first element and transmit the light to a second element and formed in a shape adapted to a predetermined geometric relationship between the first element and the second element to meet a condition of total internal reflection.

DETAILED DESCRIPTION

The following disclosure provides for many different arrangements, or examples, for implementing different features of the provided subject matter. Specific examples of components and arrangements are described below. These are, of course, merely examples and are not intended to be limiting. In the present disclosure, reference to the formation of a first feature over or on a second feature in the description that follows may include arrangements in which the first and second features are formed in direct contact, and may also include arrangements in which additional features may be formed between the first and second features, such that the first and second features may not be in direct contact. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for simplicity and clarity and does not in itself dictate a relationship between the various arrangements and/or configurations discussed.

Arrangements of the present disclosure are discussed in detail below. It should be appreciated, however, that the present disclosure provides many applicable concepts that can be embodied in a wide variety of specific contexts. The specific arrangements discussed are merely illustrative and do not limit the scope of the disclosure.

FIG.1illustrates a perspective view of an electronic module1in accordance with some arrangements of the present disclosure. In some arrangements, the electronic module1may include a light source10, a converting device11, and a substrate12. The substrate12may include a light transmitting device121, a noise cancelling device122, light paths123, and sensing units124,125,126,127, and128fabricated in or on or disposed within or on the substrate12.

In some arrangements, the light source10may include a lighting element or a lighting device that is configured to generate one or more light beams. In some arrangements, the light source10may be configured to generate a light beam having a plurality of different frequencies, such as a beam of visible light, white light, infrared (IR) light, ultraviolet (UV) light, and so on. In some arrangements, the light source10may be configured to generate a monochromatic light beam having one single wavelength. For example, the light source10may be configured to generate a laser beam or a light beam having a spectral linewidth of nearly zero. In that regard, in some arrangements, the light source10may be a laser source.

In some arrangements, the light source10may be physically spaced apart from the converting device11and the substrate12, with a gap between the light source10and the converting device11/substrate12. For example, the light source10may not be in contact with the converting device11or the substrate12. For example, the light source10, the converting device11, and the substrate12are discrete parts that are manufactured separately as separate components. In some arrangements, the light source10may be connected to the converting device11through a light transmitting element or a connection element10a. In some arrangements, the connection element10amay include a light transmitting element. In some arrangements, the connection element10amay be configured to transmit the light beam from the light source10to the converting device11. For example, the connection element10amay be configured to provide an optical path between the light source10and the converting device11. In some arrangements, the light transmitting element10amay be formed via a three-dimensional microfabrication method. For example, laser beams may be configured to focus on a predetermined location of an optical path or a connection element in a volume of a photoresist. For example, when focused into the volume of the photoresist, the laser beams may initiate two-photon polymerization via two-photon absorption and subsequent polymerization. In that regard, the light transmitting element10amay include the photoresist.

In some arrangements, the converting device11may be configured to receive a light beam from the light source10, for example, via the light transmitting element10a. In some arrangements, the converting device11may be configured to convert each light beam from the light source10into a different light beam. In some arrangements, the converting device11may be configured to modulate one or more of the frequency, amplitude, or phase of a light beam from the light source10. For example, the converting device11may be configured to convert a light beam having one frequency to a light beam having another frequency. In some arrangements, the converting device11may be configured to change the frequency band and/or frequency range of a light beam from the light source10. As used herein, a frequency band refers to an interval of frequencies in the frequency domain of a light beam and is defined by a lower frequency and an upper frequency. The description relating to frequencies/frequency bands is likewise applicable to wavelength. For example, the converting device11may be configured to change the lower frequency and/or the upper frequency of the frequency band of the light beam from the light source10(or from the light transmitting element10a). In some arrangements, the converting device11may be configured to convert a light beam having one frequency into a light beam having a plurality of frequencies. For example, the converting device11may be configured to convert or split one light beam (which may have a single frequency or a frequency band) into a plurality of light beams (each may be a monochromatic light beam having a different single frequency or be a light beam having a different frequency band). In some arrangements, the converting device11may be configured to provide one or more light beams with which the sensing units124,125,126,127, and128are configured to operate. In other arrangements, the converting device11may output the light beam from the light source10without modulating the frequency, amplitude, and phase of the light beam for one or more of the sensing units124,125,126,127, and128configured to operate with that light beam. For example, the converting device11may receive a light beam from the light source10(or the light transmitting element10a) and output another light beam having a wavelength substantially equal to the received light beam.

In some arrangements, the converting device11may include a frequency comb generator. In some arrangements, the converting device11may be configured to output or generate light beams having a plurality of frequencies arranged at an equal frequency interval (i.e., frequency comb). In some arrangements, the converting device11may be configured to output or generate a broadband optical radiation composed of equally spaced laser beams.

In some arrangements, the converting device11may include a micro resonator for effectuating nonlinear wave mixing to produce the frequencies for the frequency comb. In some arrangements, the micro resonator may include a micro resonator based on silicon (Si), fused silica (SiO2), silicon nitride (Si3N4), silicon carbide (SiC), hydrogenated amorphous silicon (a-Si:H), aluminum nitride (AlN), sapphire (Al2O3), germanium (Ge), gallium arsenide (GaAs), indium phosphide (InP) niobate (LiNbO3), lithium tantalate (LiTaO3), zinc oxide (ZnO), glass (such as high index glass, fluoride glass, telluride glass, chalcogenide glass), quartz, diamond, and so on. In some arrangements, the converting device11may further include one or more optical devices (such as a gain medium, a waveguide, a filter, a collimator, a coupler, and so on) connected with the micro resonator. The optical devices and the micro resonator of the converting device11may be connected through one or more light paths111. The light paths111may be light paths such as but not limited to the light paths123on the substrate12as described below.

In some arrangements, the converting device11may be fabricated using standard, complementary-metal-oxide-semiconductor (CMOS) compatible processes and materials. For example, the micro resonator may be made of silicon nitride (Si3N4) and may be monolithically integrated, and compatible with existing silicon fabrication technology compatible with CMOS-processing.

In some arrangements, the converting device11may be physically spaced apart from the substrate12with a gap therebetween. For example, the converting device11may not be in contact with the substrate12. In some arrangements, the converting device11may be connected to the substrate12through a light transmitting element or a connection element11a. In some arrangements, the connection element11amay include an optical routing structure. In some arrangements, the connection element11amay be configured to transmit the light beam from the converting device11to the substrate12. For example, the connection element11amay be configured to provide an optical path between the converting device11and the substrate12. For example, the light transmitting element11amay be configured to provide an optical path between the converting device11and the light transmitting device121.

In some arrangements, the substrate12may include a silicon photonics substrate or a material platform from which optical devices and/or photonic integrated circuits can be made. In some arrangements, the substrate12may include a substrate having a silicon material. In some arrangements, the substrate12may include a Silicon on Insulator (SOI) substrate including a silicon substrate, an oxide layer disposed on the silicon substrate, and a silicon layer disposed on the oxide layer. In some arrangements, the substrate12may be a light distributing device configured to direct light beams among the light transmitting device121, the noise cancelling devices122, and the sensing units124,125,126,127, and128. In some arrangements, one or more of the light transmitting device121, the noise cancelling device122, the light paths123, and the sensing units124,125,126,127,128may be fabricated in the silicon layer of the substrate12. For example, the substrate12may include a silicon base (or a silicon substrate) and a silicon oxide layer disposed on the silicon base. The substrate12may further include a waveguide in the silicon oxide layer. In some arrangements, the waveguide may include a patterned layer, such as a patterned silicon layer. In some arrangements, the waveguide may include or is operatively coupled or connected to a part of the light transmitting device121. For example, a part of the light transmitting device121may be a patterned silicon layer in the silicon oxide layer over the silicon base. The substrate12may further include a silicon oxide layer disposed on the silicon oxide layer to cover the light transmitting device121.

In some arrangements, the light transmitting device121may be configured to receive a light beam from the converting device11, e.g., via light transmitting element11a. In some arrangements, the light transmitting device121may be configured to transmit or direct one or more light beams received toward a corresponding sensing unit among the sensing units124,125,126,127, and128. For example, the light transmitting device121may be configured to transmit or direct one or more light beams having different frequencies or different frequency bands toward different sensing units. For example, the light transmitting device121may be configured to transmit or direct one or more light beams to different light paths leading to different sensing units based on the frequencies or frequency bands of the one or more light beams. For example, the light transmitting device121may be configured to filter out at least one light beam (each having a wavelength different from a wavelength of interest) from light beams having different wavelengths, such that at least one light beam having the wavelength of interest remains and is transmitted or directed to one or more corresponding ones of the sensing units124,125,126,127, and128. For example, the light transmitting device121may be configured to filter out at least one light beam (each having a wavelength band different from a wavelength of interest) from light beams having different wavelength bands, such that at least one light beam having the wavelength band of interest remains and is transmitted or directed to one or more corresponding ones of the sensing units124,125,126,127, and128. For example, the light transmitting device121may be configured to select at least a light beam having a wavelength to pass a light path leading to a sensing unit that can be operated with the light beam having the wavelength. For example, the light transmitting device121may be configured to select at least a light beam having a wavelength band to pass a light path leading to a sensing unit that can be operated with the light beam having the wavelength band.

In some arrangements, the light transmitting device121may include a demultiplexer (DMUX), such as a DMUX of an arrayed waveguide grating (AWG) type. In some arrangements, the light beam from the converting device11may be received through the light transmitting element11aand demultiplexed by the light transmitting device121.

In some arrangements, the noise cancelling device122may be connected between the light transmitting device121and each of the at least one of the sensing units124,125,126,127, and128. For example, the noise cancelling device122may be interposed in the light paths toward each of the sensing units124,125,126,127, and128. In some arrangements, the noise cancelling device122may include a micro ring structure. In some arrangements, the noise cancelling device122may include a micro ring resonator. In some arrangements, the noise cancelling device122may be configured to reduce the noise of the light beam outputted from the light transmitting device121. In some arrangements, the noise cancelling device122may be configured to interfere with the light beam constructively. For example, the noise cancelling device122may be configured to increase the intensity of the light beam outputted from the light transmitting device121. In some arrangements, two or more different kinds of noise cancelling device122may be located in the light paths moving toward different kinds of sensing units124,125,126,127, and128. For example, the noise cancelling device122between the light transmitting device121and the sensing unit124may be different from the noise cancelling device122between the light transmitting device121and the sensing unit125with respect to size, number, resonant wavelength(s), and so on.

In some arrangements, the light paths123may be configured to direct light beams among two or more of the light transmitting device121, the noise cancelling device122, and the sensing units124,125,126,127, and128. In some arrangements, the light paths123may be configured to direct light beams between the connection element11aand the light transmitting device121. In some arrangements, the light paths123and the substrate12may be made from or include different materials. In some arrangements, the light paths123and the substrate12may have different refractivities or refractive indices. In some arrangements, the light paths123may include compound semiconductors, such as III-V materials. In some arrangements, the light paths123may be formed by modifying the refractive index of silicon. Methods of modifying the refractive index of silicon may include current injection or local heating.

In some arrangements, each of the sensing units124,125,126,127, and128may include an optical sensing device (or a light sensing device), a light emitting device, or a combination thereof. In some arrangements, each of the sensing units124,125,126,127, and128may include one or more of an optical fiber sensor, a laser-based sensor, an optical chemical and biological sensor, a nanophotonic and plasmonic biosensor, a sensor for terahertz sensing, a sensor for quantum sensing, another type of optical sensor, or so on. For example, the sensing unit124may include an optical microphone, the sensing unit125may include a light detection and ranging (LiDAR), the sensing unit126may include a plasmonic filter (or a spectrometer), the sensing unit127may include a Sagnac interferometer, and the sensing unit128may include a Peptide (or an e-nose).

In some arrangements, the substrate12may include other optical devices fabricated on or in the silicon layer that generate, guide, manipulate, and/or detect light beams. Examples of optical devices may include lasers, optical modulators, photodetectors, optical switches, optical waveguides, and so on. In some arrangements, electronic devices may be fabricated in the silicon layer, along with the optical devices. Examples of electronic devices may include transistors, capacitors, resistors, and inductors. However, it should be noted that the silicon layer may include only optical devices or may include both electronic devices and optical devices.

The sensing units inFIG.1is for illustrative purposes only, and the number or the type of the sensing units is not limited thereto. In some arrangements, there may be any number or any type of sensing units in the electronic module1depending on design requirements.

In some arrangements, two or more of the sensing units124,125,126,127, and128may be configured to receive light beams having different frequencies or frequency bands. For example, the sensing unit124is configured to receive or detect light beams of a wavelength band, and the sensing unit125is configured to receive or detect light beams of another wavelength band. For example, the sensing unit124is configured to operate with light beams of a wavelength band, and the sensing unit125is configured to operate with light beams of another wavelength band. In some arrangements, two or more of the sensing units124,125,126,127, and128may be configured to radiate light beams having different frequencies or frequency bands. For example, the sensing unit124is configured to radiate light beams of a wavelength band, and the sensing unit125is configured to radiate light beams of another wavelength band. In some arrangements, a first sensing unit on the substrate12may be configured to radiate light beams and a second sensing unit on the substrate12may be configured to receive a reflecting light of the light beams (radiated by the first sensing unit) as reflected by an object outside of the electronic module1. In some arrangements, the electronic module1may further includes a light receiving device outside of the electronic module1(e.g., outside of the substrate12) and configured to receive light beams radiated by a sensing unit on the substrate12.

In some arrangements, the electronic module1may be a sensor hub that has a plurality of sensing units (such as the sensing units124,125,126,127, and128) integrated or disposed on or within the same substrate or carrier. In some arrangements, the sensing units may be integrated onto a silicon base or similar material. The packaging size is reduced at least by an order of magnitude while matching the performance of a system built with discrete components.

In some arrangements, although the plurality of sensing units are configured to operate with light beams having different frequencies or frequency ranges, the sensing units in the electronic module1may share the same light source10. For example, given that the light beams can be converted by the converting device11and demultiplexed by the light transmitting device121to a corresponding sensing unit, the sensing units in the electronic module1may share the same light source10and the feasible bandwidth can be increased. In addition, by using the light paths123, costs are minimized because additional optical fibers do not need to be deployed, which is usually quite costly.

FIG.2Aillustrates a side view of an electronic module2in accordance with some arrangements of the present disclosure. In some arrangements, a part of the electronic module1inFIG.1may include the electronic module2ofFIG.2A. The electronic module2includes at least a substrate20, electric components21and23, and a connection element22.

The electronic components21and23may be disposed on or otherwise operatively coupled to the substrate20and may be connected to one another via a connection element22. In some arrangements, the connection element22may be the connection element10aor the connection element11ainFIG.1. In some arrangements, the electronic component21may be the light source10, and the electronic component23may be the converting device11that is connected to the light source10via the connection element10a. In some arrangements, the electronic component21may be the converting device11, and the electronic component23may be one of the components (such as the light transmitting device121) on the substrate12, where the one of the components on the substrate12is connected to the converting device11via the connection element11a.

In some arrangements, the electronic components21and23may be disposed on a single substrate20as shown. In other arrangements, the electronic components21and23may be disposed on separate substrates that are physically spaced apart with a gap therebetween. For example, the substrate on which the electronic component21is disposed may not be in contact (e.g., direct contact) with the substrate on which the converting device11is disposed. For example, the substrate on which the electronic component21is disposed and the substrate on which the converting device11is disposed may be discrete parts manufactured separately.

In some arrangements, the connection element22may include an optical fiber. In some arrangements, the connection element22may include a core made of polymer (such as polymethyl methacrylate (PMMA), polycarbonate)), silica or quartz, and a cladding made of fluoropolymer or fluorinated polymer. The cladding material surrounds the core material. The cladding material may have a refractive index lower than that of the core material. In some arrangements, light may travel through the core, hit a boundary between the core and the cladding, and bounce back-and-forth off between the core and cladding at the boundary thereof. In that regard, light may be confined in the connection element22through total internal reflection. In some arrangements, the connection element22may include an optical structure22aand a trace part22bconnected with the optical structure22a.

In some arrangements, the optical structure22amay have a partial-ball shape or include a partial-ball structure. An example of the optical structure22ais a ball lens. The optical structure22amay be coupled or attached to a contact21con an active surface211of the electronic component21through an adhesive structure21a. In some arrangements, the optical structure22amay be in contact with the contact21cvia the adhesive structure21a, or alternatively in arrangements not shown, the optical structure22amay be in direct contact with the contact21c. In some arrangements, the optical structure22amay be in direct contact with the adhesive structure21aas shown. In some arrangements, the optical structure22amay be thicker in width or diameter than a width or diameter of the trace part22bso as to capture at least some of the light beams radiating from the electronic component21. As used herein, width refers to a dimension (e.g., the largest dimension) of a cross-section taken perpendicular to the direction in which the optical structure22aor the trace part22bextends, e.g., from the electronic component21to the electronic component23. In some other arrangements, the optical structure22amay be omitted and the trace part22bmay be coupled or attached to the contact21cvia the adhesive structure21a. For example, the light beams from the electronic component21may be captured by the trace part22b.

In some arrangements, the trace part22bmay include a wire structure or a wire loop. In some arrangements, the trace part22bmay be extended from the optical structure22a. In some arrangements, the trace part22bmay have one or more curved portions. In some arrangements, the trace part22bmay have one or more straight portions. In some arrangements, the trace part22bmay have a substantially uniformed width or diameter as shown. For example, the cross-section width of the trace part22bmay be consistent or unvarying throughout its entire length or a substantial portion (e.g., over 90% of the entire length). For example, the cross-section area of the trace part22bmay be consistent or unvarying throughout its entire length or a substantial portion (e.g., over 90%) of the entire length. In other arrangements, the trace part22bmay have various widths or diameters. For example, the trace part22bmay have a thinner section (with a lesser width or diameter) connected with a thicker section (with a greater width or diameter). In some arrangements, the trace part22bmay have various heights with respect to the active surface211of the electronic component21. As used herein, a height with respect to the active surface211refers to a dimension along or parallel to a direction normal to the active surface211. For example, the trace part22bmay have a proximal section closer to the active surface211of the electronic component21and a distal section farther from the active surface211of the electronic component21. In some arrangements, the trace part22bmay have various heights with respect to an active surface of the electronic component23. As used herein, a height with respect to the active surface of the electronic component23refers to a dimension along or parallel to a direction normal to the active surface of the electronic component23. In some arrangements, the trace part22bmay have various heights with respect to the substrate20. As used herein, a height with respect to the active surface of the substrate20refers to a dimension along or parallel to a direction normal to the active surface of the substrate20.

In some arrangements, the trace part22bmay have a proximal end adjacent to the optical structure22aand a distal end opposite to the proximal end. In some arrangements, the proximal end of the trace part22bmay be coupled or attached to the optical structure22a. In some arrangements, the distal end of the trace part22bmay be coupled or attached to the active surface of the electronic component23. In some arrangements, an adhesive structure (not illustrated in the figures) may be disposed between the distal end of the trace part22band the active surface of the electronic component23. In some arrangements, the distal end of the trace part22bmay have a surface221. In some arrangements, the surface221may be substantially planar. In some arrangements, the surface221and the active surface of the electronic component23may be oblique with respect to each other and may define an angle 0 less than 90degrees to facilitate the coupling of light beams between the trace part22band the electronic component23. In some arrangements, the surface221may be configured to collimate light beams between the trace part22band the electronic component23. For example, the surface221may be configured to reflect the light beams into a direction substantially perpendicular to the active surface of the electronic component23, by virtue of the angle θ.

In some arrangements, the adhesive structure21amay include a photoresist. In some arrangements, the adhesive structure21amay include a light curable material, such as a UV glue, a polymerizable composition containing photoinitiators, or so on. In some arrangements, the adhesive structure21amay have a refractive index lower than that of the core material of the connection element22. In some arrangements, the adhesive structure21amay surround the contact21con the active surface211of the electronic component21. In some arrangements, the adhesive structure21amay cover the contact21con the active surface211of the electronic component21. In some arrangements, the adhesive structure disposed between the distal end of the trace part22band the active surface of the electronic component23may be a structure such as but not limited to the adhesive structure21a.

FIG.2Billustrates an enlarged view of an electronic module in accordance with some arrangements of the present disclosure. In some arrangements, the electronic module2inFIG.2Bmay have an enlarged view of a portion ofFIG.2A. The same or similar components are annotated with the same symbols.

As shown inFIG.2B, the substrate20may include an SOI substrate including a silicon substrate20a, an oxide layer20bdisposed on the silicon substrate20a, and a silicon layer20cdisposed on the oxide layer20b. In some arrangements, a waveguide structure may be formed in the silicon layer20c. In some arrangements, the waveguide structure may include a grating or a diffraction grating as shown. For example, a grating20gmay be formed in the silicon layer20c. In some arrangements, the grating20gmay include recesses having different depths as shown. In some arrangements, the grating may include extending parts having different heights. As used herein, a height of the grating20grefers to a dimension of the grating along or parallel to a direction normal to the lower surface of the silicon layer20ccontacting the oxide layer20b. In some arrangements, the waveguide structure may be configured to facilitate the coupling of light beams between the trace part22band the electronic component23. In some arrangements, the surface221may be configured to reflect the light beams into the grating20gformed in the silicon layer20c. In some arrangements, the waveguide structure and the surface221may be configured to collimate the light beams.

In some arrangements, manufacturing the electronic module2as illustrated inFIG.2Aincludes providing (e.g., manufacturing or forming) the electronic component21and the electronic component23. The electronic component21and the electronic component23may be disposed on the same substrate20or disposed on separate substrates which are physically separated. Then, the connection element22may be formed to connect the electronic component21and the electronic component23.

In some arrangements, the connection element22may be formed by providing a core material and cutting the core material by a diamond blade into an optical fiber. One end of the optical fiber may be shaped into the optical structure22athat has a ball structure. In some arrangements, the optical structure22amay be shaped by an electric arc.

Then, the optical structure22amay be disposed on the active surface211of the electronic component21to be coupled or attached to the contact21c. For example, the optical structure22amay be spaced apart from the active surface211of the electronic component21by the contact21c. The distance and the relative direction between the optical structure22aand the active surface211should be well-controlled to meet a threshold/criterion of light input or luminous flux captured into the optical structure22a. Furthermore, the distance and the relative direction between the trace part22band the surroundings (e.g., the active surface211, the optical structure22a, the electronic component23, and the substrate20) should be well-controlled to meet a condition of total internal reflection and trap or confine light beams in the trace part22b. For example, the height of the trace part22bfrom the substrate20should be kept at a certain elevation. The condition of total internal reflection is also related to the refractive index of the connection element22and the refractive index of cladding (or air) of the connection element22. In some arrangements, the adhesive structure21amay be disposed on the contact21cbefore disposing the optical structure22a, and then the optical structure22ais provided to contact the adhesive structure21aand the contact21c. The adhesive structure21a, the contact21c, and the electronic component21may shift or rotate during pick-and-place processes, which may deteriorate the light input or luminous flux captured into the optical structure22a. To address such concerns, in the present disclosure, the distance and the relative direction between the optical structure22aand the active surface211may be predetermined by a simulation.

Then, the optical structure22aand the trace part22bmay be adaptively routed to meet a threshold/criterion of light input or luminous flux captured into the optical structure22a.

The trace part22bmay be formed by extending the trace part22bfrom the optical structure22atoward the electronic component23. The trace part22bmay be laid down to contact the electronic component23(or the waveguide structure inFIG.2B). The trace part22bmay be fixed by an adhesive structure and then cut by a diamond blade to form the angle θ.

For example, a geometric relationship (such as the distance and the relative direction) between the optical structure22aand the active surface211may be calculated and predetermined, such as through a computer simulation (e.g., a Finite Element Method (FEM) simulation). Then, the connection element22may be adapted to the geometric relationship. For example, the shape, the widths (diameters), and the heights of the connection element22may be adapted to the geometric relationship. For example, the widths and the heights of the connection element22may be designed or adjusted according to the geometric relationship. For example, the connection element22may have an adaptive auto-routed portion formed based on the geometric relationship that is calculated.

In some arrangements, the geometric relationship may include a distance, a relative elevation, a difference of respective locations, or difference of respective directions between the electronic component21and the electronic component23(taking into account the nuances of the contact21c, the adhesive structure21a, and the adhesive structure for the electronic component23as part of the electronic component21and the electronic component23). For example, the geometric relationship may include the difference between the location of the electronic component21on the substrate20and the location of the electronic component23on the substrate20. For example, the geometric relationship may include the distance between the electronic component21and the electronic component23. For example, the geometric relationship may include the relative elevation between the active surface211of the electronic component21and the active surface of the electronic component23.

In some arrangements, by adaptively routing the connection element22, misalignment caused by the geometric relationship may be compensated for. For example, misalignment between the electronic component21and the electronic component23may be adjusted by adaptively routing the connection element22.

In addition, the connection element22may be configured to satisfy connection requirements for the electronic component21and for the electronic component23. For example, the connection requirements (such as bandwidth, data rate, signal loss rate, and so on) for the electronic component21and for the electronic component23may be different. The connection element22may have one end adapted to the connection requirements for the electronic component21and another end adapted to the connection requirements for the electronic component23.

FIGS.3A,3B,3C, and3Dillustrate stages of a method of manufacturing an electronic module in accordance with some arrangements of the present disclosure. In some arrangements, at least a part of the electronic module1inFIG.1and the electronic module2inFIG.2Amay be manufactured as described below with respect to theFIGS.3A,3B,3C, and3D.

Referring toFIG.3A, a waveguide structure30may be formed on a SOI substrate including a silicon substrate (not shown inFIG.3A), an oxide layer31disposed on the silicon substrate, and a silicon layer32disposed on the oxide layer31. In some arrangements, the waveguide structure30may be formed on the converting device11inFIG.1. In some arrangements, the silicon layer32may include an electronic component formed therein.

In some arrangements, the waveguide structure30may include an encapsulant, such as a polymer. In some arrangements, the waveguide structure30may have an end301configured to connect to an optical path or a connection element (e.g., the connection elements10aand11ainFIG.1or the connection element22inFIG.2A) and an end302opposite to the end301. In other arrangements, the end301of the waveguide structure30may be adjacent to or in contact with the light source10and the connection element10amay be omitted. For example, the waveguide structure30may cover an end of an optical path or a connection element. For example, the waveguide structure30may cover a part of the light source10. For example, a width of the end301of the waveguide structure30may be thicker than a width of an optical path or a connection element so as to capture at least some of the light beams from the light source10. For example, a width of the end301of the waveguide structure30may be thicker than a width of an active area of the light source10so as to capture at least some of the light beams from the light source10. For example, the waveguide structure30may cover the surface221of the trace part22binFIG.2A. In some arrangements, the waveguide structure30may taper from the end301to the end302. For example, the end301may have a dimension (such as a thickness or a width) greater than that of the end302. In some arrangements, the waveguide structure30may be designed to reduce the dimension or scale difference between the light source10and the converting device11. In some arrangements, the waveguide structure30may be configured to facilitate the coupling of light beams between a connection element and the electronic component formed in the silicon layer32. In some arrangements, the waveguide structure30may be configured to facilitate the coupling of light beams between a connection element and the micro-ring structure in the converting device11. In some arrangements, the waveguide structure30may be configured to confine light beams between a connection element and the electronic component formed in the silicon layer32to reduce light leakage.

Referring toFIG.3B, a conductive material34may be formed on the waveguide structure30. In some arrangements, the conductive material34may be formed by sputtering conductive material (such as metal) on the waveguide structure30. In some arrangements, the waveguide structure30, the end302of the waveguide structure30, the oxide layer31, and the silicon layer32may be at least partially covered by the conductive material34.

Referring toFIG.3C, a photoresist35may be disposed on the conductive material34and patterned to form a hole35hto expose a portion of the conductive material34. In some arrangements, the photoresist35may be relatively closer to the end301than to the end302. For example, after the hole35his formed, the photoresist35may be spaced apart from the end302. For example, after the hole35his formed, the end302(covered by the conductive material34) may be exposed from the hole35h.

Referring toFIG.3D, the photoresist35may be removed. A part of the conductive material34that is exposed from the hole35hshown inFIG.3Cmay be left on a part of the waveguide structure30, a part of the oxide layer31, and a part of the silicon layer32. For example, the conductive material34may cover the end302. A part of the conductive material34that is covered by the photoresist35inFIG.3Cmay be removed, i.e., etched away.

In some arrangements, the conductive material34may be configured to contain stray light. In some arrangements, the conductive material34may help to enhance the coupling efficiency between the waveguide structure30and the electronic component formed in the silicon layer32.

FIGS.4A,4B,4C,4D,4E,4F, and4Gillustrate stages of a method of manufacturing an electronic module in accordance with some arrangements of the present disclosure. In some arrangements, a part of the electronic module1inFIG.1and the electronic module2inFIG.2Amay be manufactured by the operations described below with respect to theFIGS.4A,4B,4C,4D,4E,4F, and4G.

Referring toFIG.4A, electronic components41and42may be disposed on a carrier40. In some arrangements, the electronic component41may be the light source10, and the electronic component42may be the converting device11inFIG.1. In some arrangements, the electronic component41may be the converting device11, and electronic component42may be one of the components (such as the light transmitting device121) on the substrate12inFIG.1. In some arrangements, the electronic component41may be the electronic component21, and the electronic component42may be the electronic component23inFIG.2A. In some arrangements, the electronic components41and42may be disposed on a single substrate40as shown. In other arrangements, the electronic components41and42may be disposed on substrates that are physically spaced apart with a gap therebetween.

In some arrangements, the electronic components41and42may have different thicknesses. For example, the electronic component42may be thicker than the electronic component41. As used herein, a thickness with respect to the substrate refers to a dimension along or parallel to a direction normal to a surface of the substrate40facing the electronic components41and42. That is, the surface facing away from the carrier40(or the backside surface) of the electronic component41may be closer to the substrate40in comparison with the surface facing away from the carrier40(or the backside surface) of the electronic component42.

The active surface411of the electronic component41may be in direct contact with the carrier40. The active surface421of the electronic component42may be in direct contact with the carrier40. The active surface411of the electronic component41and the active surface421of the electronic component42may be planarized or aligned. For example, the active surface411of the electronic component41may be substantially coplanar with the active surface421of the electronic component42. For example, the active surface411of the electronic component41may be substantially parallel with the active surface421of the electronic component42. In other arrangements, the active surface411of the electronic component41and the active surface421of the electronic component42may be non-coplanar.

Referring toFIG.4B, a protection layer43may be disposed on the carrier40to cover the electronic components41and42. In some arrangements, the protection layer43may include an epoxy resin having fillers, a molding compound (e.g., an epoxy molding compound or other molding compound), a polyimide, a phenolic compound or material, a material with a silicone dispersed therein, or a combination thereof. In some arrangements, the protection layer43may be formed by compression molding, transfer molding, spin casting, spray up molding, and so on.

Referring toFIG.4C, the carrier40may be removed to expose the active surface411of the electronic component41and the active surface421of the electronic component42. A planar surface431may be defined by a surface of the protection layer43, the active surface411of the electronic component41, and the active surface421of the electronic component42. As shown, the surface of the protection layer43, the active surface411, and the active surface421are coplanar.

Referring toFIG.4D, a photoresist44may be disposed on the protection layer43to cover the planar surface431. For example, the photoresist44may be in contact with the active surface411of the electronic component41and the active surface421of the electronic component42.

Referring toFIG.4E, one or more laser beams may be applied on the photoresist44to pattern the photoresist44. In some arrangements, the laser beams45may be configured to form an optical path or a connection element (e.g., the connection elements10aand11ainFIG.1or the connection element22inFIG.2A) via a three-dimensional microfabrication method. In some arrangements, the laser beams may be configured to focus on a predetermined location of an optical path or a connection element. For example, when focused into the volume of the photoresist44, the laser beams may initiate two-photon polymerization via two-photon absorption and subsequent polymerization.

In some arrangements, the laser beams may be configured to adaptively route an optical path or a connection element between the electronic components41and42. For example, a geometric relationship between the electronic component41and the electronic component42may be calculated, such as through a computer simulation for each module as it is manufactured. Then, an optical path or a connection element may be formed and adapted to the geometric relationship. For example, the shape of a connection element may be specifically-predetermined by the geometric relationship between the electronic component41and the electronic component42.

Referring toFIG.4F, a connection element46may be formed through the three-dimensional microfabrication method inFIG.4E. In some arrangements, the connection element46may have a portion substantially parallel with the active surface411of the electronic component41and the active surface421of the electronic component42. The distance and the relative direction between the connection element46and the surroundings (e.g., the electronic component41and the electronic component42) should be well-controlled to meet a condition of total internal reflection and trap or confine light beams in the connection element46. For example, the distance, the height, or the rising range of the connection element46from the protection layer43should be kept at a certain elevation. The condition of total internal reflection is also related to the refractive index of the connection element46and the refractive index of cladding (or air) of the connection element46.

In some arrangements, planarizing or aligning the active surface411of the electronic component41and the active surface421of the electronic component42may facilitate alignment between the electronic component41and the electronic component42, which have different thicknesses. In some arrangements, disposing the photoresist44on a substantially coplanar surface431may help control the geometric relationship between the electronic component41and the electronic component42. Therefore, an adaptive auto-routed optical path or a connection element may be formed. In some arrangements, disposing the photoresist44on a substantially coplanar surface431may help reduce the length of the connection element46and minimize costs.

In addition to the structure ofFIG.4F, another structure ofFIG.4Gmay be formed (in combination with the structure ofFIG.4For alone) through the three-dimensional microfabrication method inFIG.4E.

Referring toFIG.4G, alternatively or additionally, a connection element47may be formed on the electronic component41and the electronic component42. The connection element47may have openings for coupling light beams. A shape of a cross section of the connection element47may be designed to satisfy the connection requirements for the electronic component41and for the electronic component42. For example, a shape of a cross section of the connection element47may be circular, semi-circular, rectangular, triangular, irregular, etc.

As used herein, the terms “approximately,” “substantially,” “substantial” and “about” are used to describe and account for small variations. When used in conjunction with an event or circumstance, the terms can refer to instances in which the event or circumstance occurs precisely as well as instances in which the event or circumstance occurs to a close approximation. As used herein with respect to a given value or range, the term “about” generally means within ±10%, ±5%, ±1%, or ±0.5% of the given value or range. Ranges can be expressed herein as from one endpoint to another endpoint or between two endpoints. All ranges disclosed herein are inclusive of the endpoints unless specified otherwise. The term “substantially coplanar” can refer to two surfaces within micrometers (μm) of lying along the same plane, such as within 10 μm, within 5 μm, within 1 μm, or within 0.5 μm of lying along the same plane. When referring to numerical values or characteristics as “substantially” the same, the term can refer to the values lying within ±10%, ±5%, ±1%, or ±0.5% of an average of the values.

The foregoing outlines features of several arrangements and detailed aspects of the present disclosure. The arrangements described in the present disclosure may be readily used as a basis for designing or modifying other processes and structures for carrying out the same or similar purposes and/or achieving the same or similar advantages of the arrangements introduced herein. Such equivalent constructions do not depart from the spirit and scope of the present disclosure, and various changes, substitutions, and alterations may be made without departing from the spirit and scope of the present disclosure.