Optical module and method of manufacturing the same

An optical module includes a first silicon substrate having a first groove at its surface, a second silicon substrate having a second groove at its surface, a Laser device formed on the first silicon substrate, an optical modulator formed on the second silicon substrate, a substrate on which the first and the second silicon substrates are mounted wherein an optical axis of the Laser device is matched up with an optical axis of the optical modulator, a first lens transforming an divergent light emitted from the first optical device into a parallel light, disposed in the first groove, and a second lens converging the parallel light to the second optical device, disposed in the first groove.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the priority benefit of Japanese Patent Application No. 2007-084142, filed Mar. 28, 2007, the entire disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to an optical module having lenses and a optical modulation device mounted on a surface of a silicon substrate, and a method of manufacturing the optical module.

2. Description of the Related Art

Many optical modules having lenses and a optical modulation device mounted on a surface of a silicon substrate are proposed. Some of them are disclosed in the following Japanese Patent Publication References.

JP H08-201660A (hereinafter referred as the Reference 1)

JP H09-211274A (hereinafter referred as the Reference 2)

JP 2004-093660A (hereinafter referred as the Reference 3)

According to the Reference 1, an optical module having a following structure is disclosed. The optical module disclosed in the Reference 1 includes a first V-letter shaped groove and a second V-letter shaped groove perpendicular to the first groove, both of which are formed in a silicon substrate. One end of an optical fiber is fixed at the first groove, and a light emitting device is mounted along the optical axis of the optical fiber with the relatively soft accuracy. A ball lens is placed in the second groove. In order to adjust the optical relationship among the light emitting device, the ball lens and the optical fiber, the ball lens is moved along the second groove while the light emitting device is in operation. The light beam emitted from the light emitting device is converged by the ball lens, and is entered into the optical fiber. As a result, by measuring the coupling condition among the light emitting device, the ball lens and the optical fiber, the optical relationship among them is adjusted in the most appropriate condition.

In the field of the long distance optical communication, it is required to use a transmitter, which has small wavelength chirp, as a lighting source, because the wavelength dispersion characteristics, which are inherent in the optical fiber as the transmission medium, deteriorates the communication quality in which a little fluctuation of the communication wavelength makes large distortion to the transmittal waveform. Even if a Distributed Feed-Back type Laser device (hereinafter called a DFB Laser device) is used as a lighting source, an external modulator system such as an Electro-Absorption (EA) semiconductor modulator or a Mach-Zehnder type modulator using Lithium Niobe Oxide (LiNbO3) or Indium Phosphide (InP) compound semiconductor is generally used because an oscillation wavelength of the DFB Laser device is easily fluctuated in a direct modulation system in which the injected current is directly transformed.

Under the external modulator system, because the modulation control of the input/output of light is performed by the external devices, the injected current of the DFB Laser device can be used as the constant optical output without transforming injected current. Thus, a single waveform oscillation having small wavelength chirp can be fulfilled. In recent years, a device in which a DFB Laser device and an EA modulator element are monolithically-integrated is frequently used so that an assembling cost or an area to be assembled can be reduced.

On the other hand, in a dense wavelength division multiplexing (DWDM) transmitting system, which is superior for the expandability of the communication capacity, it is necessary to suppress the cross-talk between the light signals, each of which is adjacent to each other with an extremely narrow wavelength interval, due to the trend of the multiple wavelength by segmentalizing the band wavelength. For this reason, the stabilization of each signal wavelength becomes one of the most important issues to be resolved. However, when the number of the communication wavelength is increased because of the segmentation of the optical wavelength, it is required to prepare the devices of the particular number, which is the same as the number of the wavelength sued in the system, on the basis that a band-gap wavelength of an absorber layer in the EA modulator element is designed to match up with each communication wavelength and is provided in the modulator in which the EA modulator element is used. As a result, increasing the cost for the development, the manufacture and the management of the stocks is unavoidable. Thus, it is considered that there is a limit to apply the EA modulator element in the DWDM transmitting system. Furthermore, while the oscillation wavelength of the DFB Laser device is changed in the rate of 1 Å/° C., the bang-gap wavelength of the EA modulator element is changed in the rate of 4˜5 Å/° C. Thus, in order to avoid shifting a wavelength-detuning, which means that the band-gap wavelength of the absorber layer in the EA modulator element matches up with the oscillation wavelength of the DFB Laser device, it is required to control the temperature of each of the DFB Laser device and the EA modulator element, rigorously. To resolve this problem, a modulator using a Mach-Zehnder type modulator element starts to garner attention.

Since the Mach-Zehnder type modulator element has small wavelength chirp, and it can covers a wide range of wavelength domain as a single device, it is suitable for the long distance and multiple-wavelength transmission system. By the monolithic or the hybrid integration of the DFB Laser device with the Mach-Zehnder type modulator element, it is possible to reduce the number of the device group being prepared for the number of the wavelength used in the system. As a result, it is possible to reduce the cost for the development, the manufacture and the management of the stocks.

The hybrid integration structure of the DFB Laser device with the Mach-Zehnder type modulator element serve as a typical example used in the long distance and multiple-wavelength transmission system is explained as follows with reference toFIG. 6.FIG. 6is a side view showing a frame format of the conventional optical module disclosed in the Reference 2.

The optical module shown inFIG. 6is a device hybridly integrating a DFB Laser device1with a Mach-Zehnder type modulator element2. The DFB Laser device1mounted on a first carrier3and the Mach-Zehnder type modulator element2mounted on a second carrier4are optically coupled to each other by a first lens5having a holder and a second lens6having a holder. The first lens5and the second lens6are centered along their cores in the three axis directions on a first lens core adjuster7and a second lens core adjuster8, respectively, and then, these adjusters7and8are fixed by the YAG Laser weld on a stainless base carrier9.

Further, a tube-shaped isolator10, which passes light in one direction, is disposed between the first and the second lenses, and is fixed on supporting member11by the YAG Laser weld. Moreover, a compensation lens12having a holder, which optically adjusts the slight dislocation of the centering for the cores of the lenses7and8, is disposed between the lenses7and8. The compensation lens12is fixed by the YAG Laser weld on the stainless base carrier9via a compensation lens adjuster13after the adjustment of the dislocation of the centering for the cores of the lenses7and8. As described in the Reference 2, when the compensation lens12having a large curvature radius is used, it is possible to perform the fine adjustment of the angle of the focused laser beam with a rough centering process. Thus, by suing the compensation lens12having a large curvature radius, the adjustment of the slight dislocation can be easily fixed.

After a third lens14having a holder is centered along its cores with the cores of the first and the second lenses7and8in the three axis directions in order to couple an optical signal outputted from the Mach-Zehnder type modulator element2with an optical fiber16having a built-in lens, which is disposed outside a package15, it is fixed by the YAG Laser weld on the stainless base carrier9via a third lens adjuster17. The stainless base carrier9is fixed by solder on a thermal electro cooler18disposed in the package15

The DFB Laser device1outputting a uniform light is thermally controlled by thermal electro cooler18in order to oscillate a single waveform constantly. The Mach-Zehnder type modulator element2is electrically controlled by a high-speed modulation signal outputted from a driver IC, and is functioned as a shutter either for passing through or blocking the laser light from the DFB Laser device1.

However, the optical module shown inFIG. 6has following issues. First, since a spot size of the light in each of the DFB Laser device1and the Mach-Zehnder type modulator element2is very small such as around 1 μm and since a tolerance of the dislocating of the centering for the cores of them is very strict, the accuracy required for centering the cores of lenses should be within an accuracy of sub-micrometers. In fact, because of the use of the compensation lens12, the accuracy is eased to an accuracy of micrometers. However, since the range of the adjustment by the compensation lens12is not so wide, the DFB Laser device1, the first lens5, the second lens, and the Mach-Zehnder type modulator element2should be disposed to an accuracy of micrometers in order to obtain the fine optical coupling efficiency.

It is not easy for the hybrid structure having a plurality of components illustrated inFIG. 6to dispose the components at the locations to an accuracy of micrometers. For this reason, new assemble process utilizing an image or a marker-recognition is introduced, or the strict management as to the size of each component to be mounted is required. As a result, the cost for the accurate process or the inspection of the components or the cost for accurate mounting the components increases.

The second issue relates to the method of fixing the lenses. As described above, the first lens5and the second lens6are fixed by the YAG Laser weld on a stainless base carrier9via each of the adjusters7and8after they are centered along their cores in the three axis directions. Because of the inherency of the YAG Laser weld, the melted metal is condensed at the time of the natural cooling so that it is not easy to place the lenses at the location to an accuracy of micrometers. Thus, the dislocation of the centering for the cores of the lenses7and8caused at the time of the YAG Laser weld is adjusted by the compensation lens12. However, since the compensation lens12having the large curvature radius is lens-shaped, while it has ability for fine adjustment of the angle of the focused laser beam with a rough centering process, it has little ability for focusing the light. Thus, the compensation lens12cannot adjust the dislocation in the optical axis direction. For this reason, it is still required to dispose the lenses in the optical axis direction to an accuracy of sub-micrometers.

In order to avid these issues, an optical module disposed in the Reference 3 is proposed. According to the optical module disclosed in the Reference 3, a V-letter shaped groove is formed at a surface of a silicon substrate, and a spot shape changeable element, a first and a second lens elements, an EA modulator, a Laser diode, and optical fiber are mounted along the V-letter shaped groove. The Laser diode and the EA modulator are optically coupled by the first lens element, and the EA modulator and the optical fiber are optically coupled by the spot shape changeable element and the second lens element. The EA modulator includes a waveguide structure and it has a rectangularily-shaped core at its cross-sectional view. The spot of the light outputted from the core is elliptically-shaped.

The divergent light having the elliptically-shaped spot outputted from the Laser diode is focused by the first lens element and the focused divergent light still having the elliptically-shaped spot is injected into the core of the EA modulator. The divergent light having the elliptically-shaped spot outputted from the core is changed to the parallel light having the circularly-shape spot, and then the parallel light having the circularly-shape spot is transformed into the convergent light by the second lens element. Finally the convergent light is injected into the optical fiber.

According to the optical module disclosed in the Reference 3, since the spot shape changeable element and the lens elements are disposed between the EA modulator and the optical fiber, the parallel light having the circularly-shape spot, which is changed from the divergent light having the elliptically-shaped spot outputted from the core of the EA modulator, can be injected into the optical fiber. As a result, the coupling efficiency can be dramatically improved. Further, since the spot shape changeable element includes an adjustment member whose shape is suitable for the silicon substrate, no holder is required for the lenses and the lenses are easily mounted in the V-letter shaped groove in a short amount of time. Thus, the cost can be reduced. Moreover, the lenses disclosed in the References 1 and 2 are used, it is required to have a wiring distance sufficient to apply the bias voltage to the EA modulator. However, according the optical module disclosed in the Reference 3, the wiring distance can be the same as that in the case that the spot shape changeable element and the lens elements are not used. Thus, the deterioration of the modulation characteristic can be avoided. As a result, the optical components can be effectively coupled to each other.

However, the optical module disclosed in the Reference 3 has another issue as follows. Generally, after mounting the EA modulator and the Laser diode on the silicon substrate, burn-in tests are performed to detect an incipient failure on the EA modulator or the Laser diode in advance. Since the EA modulator and the Laser diode are mounted on the single silicon substrate, the device that both of the first burn-in test for the relationship between the Laser diode and its wire and the second burn-in test for the relationship between the EA modulator and its wire are passed can only be judged as the non-defective products so that the yield rate is deteriorated.

SUMMARY OF THE INVENTION

An objective of the invention is to solve the above-described problem and to provide an optical module whose yield rate is increased, whose reliability is high, whose manufacturing process is simple, whose cost is cheap and whose size is small.

The objective is achieved by an optical module including a first silicon substrate having a first groove at its surface, a second silicon substrate having a second groove at its surface, a Laser device mounted on the first silicon substrate, an optical modulator mounted on the second silicon substrate, a substrate on which the first and the second silicon substrates are mounted wherein an optical axis of the Laser device is matched up with an optical axis of the optical modulator, a first lens transforming an divergent light emitted from the first optical device into a parallel light, disposed in the first groove, and a second lens converging the parallel light to the second optical device, disposed in the first groove.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The first through fourth embodiments of the invention is explained together with drawings as follows. In each drawing, the same reference numbers designate the same or similar components through all embodiments.

The First Embodiment

[Structure of an Optical Module]

FIG. 1Ais a plan view of an optical module, according to a first embodiment, andFIG. 1Bis a cross-sectional view of the optical module illustrated inFIG. 1, taken along with line A-A′.

An optical module100includes a first silicon substrate20on which an optical semiconductor device23is mounted, a second silicon substrate30on which another optical semiconductor33device is mounted, which faces to the first silicon substrate20, and a substrate40, such as a stainless base carrier (hereinafter called a SUS base carrier40), for fixing the first silicon substrate20and the second silicon substrate30thereon, which are spaced to each other, and are disposed along the same optical axis.

A first wiring21, which is a conductive pattern, is formed on the surface of the first silicon substrate20at one end side, and a first groove22being nearly V-letter shape at its cross sectional view (hereinafter it is called a first V-letter shaped groove) is formed on the surface of the first silicon substrate20at the other end side. The first V-letter shaped groove22is formed for matching up the optical axis emitted from the optical device of its own with the optical axis emitted from the optical device mounted on the second silicon substrate30. On the surface of the first silicon substrate20, the optical semiconductor device23, such as a Laser device, like a semiconductor Laser or a Laser diode (hereinafter called a Laser device23), are mounted, and the optical semiconductor device23is electrically connected to the first wiring21. A first lens24for transforming the divergent light from the Laser device23to the parallel light is placed in the first V-letter shaped groove22. The first lens24is formed by a compact collimated lens or a ball lens.

The Laser device23is mounted with a high degree of accuracy at the predetermined location on the first silicon substrate20by using an image-recognition technique or a mechanical positioning control system. On the first silicon substrate20, a surface-mounted type front drive lens coupler is formed by disposing the first lens24in the first groove22by using the image-recognition technique or the mechanical positioning control system in order to set a distance between a luminous surface of the Laser device23and the surface of the first lens24to an appropriate coupling length. Since the V-letter shaped groove22is formed at the surface of the first silicon substrate20with a high degree of accuracy by the wet etching process, such as the alkali etching, by placing the first lens in the first V-letter shaped groove, it is possible to make the accurate mechanical positioning of it with the Laser device23, which is also mounted with a high degree of accuracy.

A second wiring31, which is a conductive pattern, is formed on the surface of the second silicon substrate30at the other end side, and a second groove32being nearly V-letter shape at its cross sectional view (hereinafter it is called a second V-letter shaped groove) is formed on the surface of the second silicon substrate30at the other end side. The second V-letter shaped groove32is formed for matching up the optical axis emitted from the optical device of its own with the optical axis emitted from the optical device mounted on the first silicon substrate30. On the surface of the second silicon substrate30, the optical semiconductor device33, such as an optical modulator (hereinafter called an optical modulator33), which modulates the beam outputted from the Laser device23in response to an external signal, are mounted, and the optical modulator33is electrically connected to the second wiring31. A second lens34for condensing the parallel light outputted from the first lens24at the optical modulator33is placed in the second V-letter shaped groove32. The second lens34is formed by a compact condenser lens or a ball lens.

The optical modulator33is formed by a Mach-Zehnder type optical modulator. Compared with the Laser device23, the Mach-Zehnder type optical modulator has less refractive index dispersion (wavelength dispersion). The optical modulator33is mounted with a high degree of accuracy at the predetermined location on the second silicon substrate30by using the image-recognition technique or the mechanical positioning control system. In order to set a distance between a light receiving surface of the optical modulator33and the surface of the second lens34to an appropriate coupling length, the optical adjustment process is performed by sliding the second lens34along the V-letter shaped groove32. As to the adjustment of the direction vertical to the optical axis, it is performed by placing the second lens34mechanically in the V-letter shaped groove32. By the mounting these components on the second silicon substrate30, a surface-mounted type rear drive lens coupler is formed on the second silicon substrate30.

The SUS base carrier40includes a first mounting area41on its surface at one end on which the first silicon substrate20is to be mounted, a second mounting area42on its surface at the other end on which the second silicon substrate30is to be mounted, and a cavity area43located between the first and the second mounting areas. The first silicon substrate20is fixed on the substrate40in the first mounting area41by jointing material44, such as glue or solder, and the second silicon substrate30is also fixed on the substrate40in the second mounting area42by jointing material45, such as glue or solder. A compensation lens50for optically adjusting the optical dislocation of the first and the second lenses24and34is fixed by resin adhesive material on the bottom surface of the cavity area43in an area, which is closer to the second mounting area42. An isolator51, such as a compact isolator, for passing through the parallel light outputted from the first lens24in one direction and applying it to the compensation lens50, is fixed by resin adhesive material on the bottom surface of the cavity area43in another area, which is closer to the first mounting area41, that is located between the first lens24and the compensation lens50. The variation in thickness of the first and the second silicon substrates20and30in their manufacturing process, which is in the range between 10 μm and 25 μm, is equivalent to the thickness fluctuation of a silicon wafer. Since such a variation in thickness is small, the dislocation in height comparative to the optical effective range of the isolator51so that the isolator51is easily positioned mechanically to the predetermined location. Further, since the second lens34is fixed in the second V-letter shaped groove32by the resin after centering the optical axis thereof, the dislocation of the second lens at the time of the mounting it is hardly occurred, compared with fixing the second lens by the YAG Laser weld. Thus, it is possible to fix the second lens34at the desired location with a high degree of accuracy without performing the adjustment in the optical axis direction. On the other hand, the optical adjustment of the compensation lens51is performed in the direction only which is perpendicular to the optical axis direction. Thus, numbers of components used for the adjustment, such as lens holder, can be reduced. Further, by fixing the compensation lens51at the end of the isolator51with resin, the cost and space can be reduced.

The optical module shown inFIGS. 1A and 1Bis manufactured in the following steps (a)˜(j). The manufacturing process of the optical module is explained with reference toFIGS. 2A˜2I.(a): First Step

As shown inFIG. 2A, initially, the first silicon substrate20is prepared. Then, the first V-letter shaped groove22is formed on the surface of the first silicon substrate20by a wet etching process, such as the alkali etching. Then, the first wiring21formed of a copper foil wiring pattern is formed by the photolithography. The Laser device23is positioned and mounted on the first silicon substrate20. As described above, the Laser device23is mounted with a high degree of accuracy at the predetermined location on the first silicon substrate20by using the image-recognition technique or the mechanical positioning control system.(b): Second Step

As shown inFIG. 2B, the Laser device23is electrically connected to the first wiring21by solder.(c): Third Step

As shown inFIG. 2C, a first burn-in test for the relationship between the Laser diode23and the first wire21is performed by using a tester. If necessary, the operation of the Laser diode23may be tested by applying the predetermined voltage to the Laser diode23.(d): Fourth Step

As shown inFIG. 2D, initially, the second silicon substrate30is prepared. Then, the second V-letter shaped groove32is formed on the surface of the second silicon substrate30by a wet etching process, such as the alkali etching. Then, the second wiring31formed of a copper foil wiring pattern is formed by the photolithography. The optical modulator33is positioned and mounted on the second silicon substrate30. As described above, the optical modulator33is mounted with a high degree of accuracy at the predetermined location on the second silicon substrate30by using the image-recognition technique or the mechanical positioning control system.(e): Fifth Step

As shown inFIG. 2E, the optical modulator33is electrically connected to the second wiring31by solder.(f): Sixth Step

As shown inFIG. 2F, a second burn-in test for the relationship between the optical modulator33and the second wire31is performed by using the tester. If necessary, the operation of the optical modulator33may be tested by inputting the predetermined signal or light to the optical modulator33.(g): Seventh Step

The first and the second silicon substrates20and30are aligned along the centers of each the first and the second V-letter shaped grooves22and32. The method of aligning the first and the second silicon substrates20and30is explained as follows with reference toFIG. 2G.

FIG. 2Gis a conceptual cross-sectional view of the optical module100illustrated inFIG. 1Bin-process for explaining the method of aligning a center of the V-letter shaped groove22formed in a first silicon substrate20with a center of the V-letter shaped groove32formed in a second silicon substrate30. After performing the third step and the sixth step, the first and the second silicon substrates20and30are mounted on the SUS base carrier40by aligning the optical axis of the first silicon substrate20with the optical axis of the second silicon substrate30in the following process.

First, the first silicon substrate20on which the Laser device23is mounted and the second silicon substrate30on which the optical modulator33is mounted are mounted at the predetermined approximate locations on the first mounting area41and on the second mounting area42. Then, a guide member60, which is linear-shaped, such as a circular cylinder, as shown inFIG. 2, is placed in the first and the second V-letter shaped grooves22and32, and the guide member60is pressed from above. Specifically, the guide member60is pressed at two areas where the first and the second V-letter shaped grooves22and32are located underneath, simultaneously. The centers of the first and the second V-letter shaped grooves22and32are aligned linearly along the guide member60so that the Laser device23and the optical modulator33are aligned in the correct relative position, accurately.

Since the optical axis of the Laser device23can be easily positioned mechanically with the optical axis of the optical modulator33by simply using the first and the second V-letter shaped grooves2, the optical coupling adjustment, which was a demanding task in the past, can be made easily. Then, while the first silicon substrate20and the second silicon substrate30are pressed by the guide member60, the first silicon substrate20and the second silicon substrate30are fixed by solder or resin44,45on the first and second mounting areas, respectively, so that each component used for the lens adjustment is aligned in the correct relative position.(h): Eighth Step

As shown inFIG. 2H, after performing the seventh Step, the first lens24is placed and positioned in the first V-letter shaped groove22by using the image-recognition technique or the mechanical positioning control system in order to set a distance between a luminous surface of the Laser device23and the surface of the first lens24to an appropriate coupling length, and then is fixed in the first V-letter shaped groove22by resin. As described above, since the first V-letter shaped groove22is formed with a high degree of accuracy because of its manufacturing process using the wet etching, it is possible to align mechanically the first lens24positioned in the first V-letter shaped groove22with the Laser device23, which is disposed with a high degree of accuracy.(i): Ninth Step

As shown inFIG. 2I, after performing the seventh Step, the second lens34is placed in the second V-letter shaped groove32. In order to set a distance between a light receiving surface of the optical modulator33and the surface of the second lens34to an appropriate coupling length, the optical adjustment process is performed by sliding the second lens34along the V-letter shaped groove32. As to the adjustment of the direction vertical to the optical axis, it is performed by placing the second lens34mechanically in the V-letter shaped groove32, and finally, the second lens34is fixed in the V-letter shaped groove32by resin.(j): Tenth Step

As shown inFIG. 1B, after performing the ninth step, the compensation lens50for optically adjusting the optical dislocation of the first and the second lenses24and34is disposed between the first and the second lenses24and34on the bottom surface of the cavity area43in an area, which is closer to the second mounting area42, and the compensation lens50may be fixed by resin.

The isolator51, such as a compact isolator, for passing through the parallel light outputted from the first lens24in one direction and applying it to the compensation lens50, is disposed between the first lens24and the compensation lens50on the bottom surface of the cavity area43in another area, which is closer to the first mounting area41, and the isolator may be fixed by resin.

The variation in thickness of the first and the second silicon substrates20and30in their manufacturing process, which is in the range between 10 and 25 μm, is equivalent to the thickness fluctuation of a silicon wafer. Since such a variation in thickness is small, the dislocation in height comparative to the optical effective range of the isolator51so that the isolator51is easily positioned mechanically to the predetermined location. On the other hand, the optical adjustment of the compensation lens51is performed in the direction only which is perpendicular to the optical axis direction.

According to the optical module of the first embodiment, the following benefits (1)˜(3) can be expected.

(1): While the Laser device23is mounted on the first silicon substrate20, the optical modulator33is mounted on the second substrate30, which is different from the first silicon substrate20. And then, the first and the second silicon substrates20and30are mounted in the first and the second mounting areas41and42, respectively, so that the optical axis of the Laser device23is matched up with the optical axis of the optical modulator33. According to the structure described above, since the Laser device23and the optical modulator33are mounted on the different silicon substrates, such as the first silicon substrate20and the second silicon substrate30, respectively, the burn-in test can be performed to the Laser device23and the optical modulator33, separately. Thus, when one of the first silicon substrates20each having the Laser device23to be tested passes the first burn-in test, and one of the second silicon substrates30each having the optical modulator33to be tested does not pass the second burn-in test, the first silicon substrate20having the passing Laser device23can be mounted on the SUS base carrier40. As described in the BACKGROUND OF THE INVENTION, according to the conventional optical module, since the Laser device and the optical modulator are mounted on the single silicon substrate, even if one of the Laser device and the optical modulator is judged as a non-defective, both of the Laser device and the optical modulator is judged as a defective product because they are mounted on the single silicon substrate. However, according to the optical module of the first embodiment, since the Laser device23and the optical modulator33are mounted on the different silicon substrates, the burn-in test can be performed separately. Thus, the yield rate is improved.

(2): Generally, since a Laser device23has a wide range of the refractive index dispersion, it is required to prepare many kinds of Laser devices23such as for 1.3 μm range or for 1.5 μm range in response to the wavelength to be outputted. On the other hand, since an optical modulator has a narrow range of the refractive index dispersion, the optical modulator33can be combined with the Laser device23having a wavelength, which is different from the wavelength of the optical modulator33. Thus, one of the characteristics of the optical module of the first invention is that the optical components having a different general versatility are mounted on the different silicon substrates.

(3): Since the surface-mounted type lens coupling structure with the use of the silicon substrate is employed in the first embodiment, it is possible to reduce the process for mounting the component, which requires the optical adjustment. The process effectiveness can be improved. Further, the cost can be reduced by reducing the numbers of the components, and the total size can be shrunken by mounting the components within a limited space. As a result, it is possible to provide an optical module whose reliability is high, whose manufacturing process is simple, whose cost is cheap and whose size is small.

The Second Embodiment

FIG. 3is a plan view of an optical module200, according to a second embodiment. A second silicon substrate30includes a second V-letters shaped groove32on its surface at one end and a third groove35being nearly V-letter shape at its cross sectional view (hereinafter it is called a third V-letter shaped groove) on its surface at the other end. Thus, an optical modulator33is disposed between the second and the third V-letter shaped grooves32and35. A third lens36is disposed in the third V-letter shaped groove35. The second lens34, the optical modulator33and the third lens36are disposed along the same optical axis. The third lens36is formed by a compact collimated lens or a ball lens. The other components used in the optical module200of the second embodiment are the same as those used in the optical module100of the first embodiment.

The second and the third V-letter shaped grooves32and35are formed simultaneously, and as well as the other lenses, the third lens36is fixed by resin in the third V-letter shaped groove35. The method of manufacturing the other components used in the optical module200of the second embodiment is the same as that of the first embodiment.

According to the optical module200of the second embodiment, by placing and positioning the third lens36in the first V-letter shaped groove22by using the image-recognition technique or the mechanical positioning control system in order to set a distance between a luminous surface of the optical modulator33and the surface of the third lens36to an appropriate coupling length, the third lens36can be mounted with a high degree of accuracy without performing the optical adjustment to the optical modulator33so that the process effectiveness can be improved.

The Third Embodiment

FIG. 4is a plan view of an optical module, according to a third embodiment. The optical module300includes a first silicon substrate20having a fourth groove27being nearly V-letter shape at its cross sectional view (hereinafter it is called a fourth V-letter shaped groove), whose width is narrower than that of a first V-letter shaped groove22, and a first optical bare fiber28disposed in the fourth V-letter shaped groove27, instead of the Laser device23and the first wiring21used in the optical module100in the first embodiment. The optical module300further includes a second silicon substrate30having a fifth groove237being nearly V-letter shape at its cross sectional view (hereinafter it is called a fifth V-letter shaped groove), whose width is narrower than that of a second V-letter shaped groove32, and a second optical bare fiber38disposed in the fifth V-letter shaped groove37, instead of the optical modulator33and the second wiring31used in the optical module100in the first embodiment. The fourth and the fifth V-letter shaped grooves27and37are formed by the wet etching process so that they are formed in the accurate shapes and locations. The other components and a method of manufacturing the optical module300using the other components used in the optical module300of the third embodiment is the same as those of the first embodiment.

Thus, according to the third embodiment, the first silicon substrate20further includes the first V-letter shaped groove22and the first lens24disposed in the first V-letter shaped groove22. On the first silicon substrate20, a surface-mounted type front drive lens coupler is formed by disposing the first lens24in the first groove22and by disposing the first optical bare fiber28in the fourth groove27by using the image-recognition technique or the mechanical positioning control system in order to set a distance between a luminous surface of the first optical bare fiber28and the surface of the first lens24to an appropriate coupling length.

As well as the first silicon substrate20, according to the third embodiment, the second silicon substrate30further includes the second V-letter shaped groove22and the second lens34disposed in the second V-letter shaped groove32. In order to set a distance between a luminous surface of the second optical bare fiber38and the surface of the second lens34to an appropriate coupling length, the optical adjustment process is performed by sliding the second lens34along the V-letter shaped groove32or/and by sliding the second optical bare fiber38along the fifth V-letter shaped groove37. As a result, a surface-mounted type rear drive lens coupler is formed on the second silicon substrate30.

It is possible that an optical functional component, such as a beam splitter52acting as a coupler having directional property, is disposed between the first and the second lenses24and34in addition to the compact isolator51. Thus, the optical module300can be applied for taking the monitoring light out and for dividing and consolidating the optical waveform. A compensation lens50for optically adjusting the optical dislocation of the first and the second optical fibers28and38is fixed by resin adhesive material at one end of the beam splitter52.

The surface-mounted type from drive lens coupler is not limited to the structure described above, and it is suitable for the surface-mounted type from drive lens coupler to have a combination with an optical semiconductor device including a Laser device23.

As described above, the same benefit applied to the first embodiment can be expected to the optical module300of the third embodiment.

The Fourth Embodiment

FIG. 5is a conceptual cross-sectional view of an optical module400, according to a fourth embodiment, for explaining a method of fixing a lens wherein the lens used in the fourth embodiment is the same as the lens used in the optical module of the first embodiment.

According to the optical module400, a first lens is covered by a third silicon substrate70. The third silicon substrate70includes a sixth groove72being nearly V-letter shape at its cross sectional view (hereinafter it is called a sixth V-letter shaped groove), which is to be faced to a first V-shaped groove22. The anchorage strength of the first lens24is increased by covering the first lens24with the third silicon substrate70at its sixth V-letter shaped groove72.

The first lens24is fixed by resin in the first V-shaped groove22at one of its etched slope faces or both of its etched slope faces. Since the coefficient of thermal expansion of the first lens24made of glass, which is almost 10 ppm/° C., is higher than that of a first silicon substrate20, which is 3 ppm/° C., stress may be occurred between the first lens24and the silicon substrate20by the expansion/contraction of the first lens24in response to temperature change. As a result, the resin between the first lens24and the first silicon substrate20may be peeled off. To resolve this problem, by covering the first lens24with the third silicon substrate70, the first lens24is held by the first silicon substrate20and the third silicon substrate70at four contacting points, which are two etched slope faces of the first silicon substrate20and two etched slope faces of the third silicon substrate70.

The first silicon substrate20and the third silicon substrate70are fixed by the resin or solder at their contacting faces73. Each of the widths of the first and sixth V-shaped grooves22and72is set to have the four contacting points with the first lens24all the time in the temperature range under the normal use, and to have a predetermined gap formed at the contacting faces73between the first silicon substrate20and the third silicon substrate70. For example, since the coefficient of thermal expansion of the resin used to fix the first silicon substrate20and the third silicon substrate70is very high, such as few tens ppm/° C., the gap at the contacting faces73is expanded or contracted. Thus, the resin at the contacting faces73is acted as a buffer so that the stress, which may cause the resin between the first lens24and the first silicon substrate20to be peeled, can be absorbed by the buffer. Thus, the deterioration of the coupling characteristic caused by peeling the resin off can be avoided.

The third silicon substrate70can be applied to cover the second lens34in all embodiments, and also be applied to cover the third lens36used in the second embodiment.

While the invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Thus, shapes, size and physical relationship of each component are roughly illustrated so the scope of the invention should not be construed to be limited to them. Further, to clarify the components of the invention, hatching is partially omitted in the cross-sectional views. Moreover, the numerical description in the embodiment described above is one of the preferred examples in the preferred embodiment so that the scope of the invention should not be construed to limit to them. For example, it is possible to exchange the Laser device23and the optical modulator33to other optical semiconductor devices through all embodiments. Further, the compact isolator51or the compensation lens50can be omitted, and it is also possible to exchange the compact isolator51or the compensation lens50to other optical semiconductor devices through all embodiments. Moreover, it is possible to change the illustrative shape or the illustrative structure of the optical module through all embodiments as a whole, and another method using other material or processes can be applied.

Various other modifications of the illustrated embodiment will be apparent to those skilled in the art on reference to this description. Therefore, the appended claims are intended to cover any such modifications or embodiments as fall within the true scope of the invention.