OPTICAL PACKAGE DEVICE AND METHOD OF MANUFACTURING THE SAME

An optical package device and a method of manufacturing the same are disclosed. The optical package device includes an optical component and an optical guiding component. The optical component is configured to change a phase of an input optical signal from a first state to a second state, and to output a first beam with a phase of the second state. The optical guiding component is disposed adjacent to the optical component, the first beam propagating from the optical component toward the optical guiding component. The physical axis of the optical component perpendicular thereto is not parallel with a physical axis of the optical guiding component perpendicular thereto.

BACKGROUND

1. Field of the Disclosure

The present disclosure relates to an optical package device and a method of manufacturing the same.

2. Description of the Related Art

The assembly of an optical module relies on several alignment steps. Any offset or misalignment occurring in the alignment steps would cause an unacceptable amount of error to accumulate.

SUMMARY

In some embodiments, an optical package device includes an optical component and an optical guiding component. The optical component is configured to change a phase of an input optical signal from a first state to a second state, and to output a first beam with a phase of the second state. The optical guiding component is disposed adjacent to the optical component, the first beam propagating from the optical component toward the optical guiding component. The physical axis of the optical component perpendicular thereto is not parallel with a physical axis of the optical guiding component perpendicular thereto.

In some embodiments, an optical package device includes a carrier, a lid, and an optical phase array. The lid is disposed over the carrier and has an opening. The carrier and the lid collectively define a cavity. The optical phase array is disposed in the cavity and configured to change a phase of an input optical signal from a first state to a second state, and to output a first beam with a phase of the second state. The first beam propagates through the opening of lid.

In some embodiments, a method of manufacturing an optical package device includes disposing an optical source over an optical component through a first alignment; attaching the optical component to a carrier; and attaching a lid to the carrier through a second alignment to surround the optical component.

DETAILED DESCRIPTION

FIG.1is a cross-sectional view of an optical package device100A in accordance with some embodiments of the present disclosure. The optical package device100A may include a carrier10, a lid11, an adhesive layer12, and an optical component13.

The carrier10may be disposed below the lid11. The carrier10and the lid structure11may collectively define a cavity (or a chamber) C1to accommodate the optical component13. The carrier10may have an upper surface101and a lower surface102opposite to the upper surface101. The carrier10may include a plurality of pads10cat the lower surface102. The pads10cmay be configured to connect with an external device, system, or carrier through a connection element (e.g., a solder bump).

In some embodiments, the carrier10may include a lead frame encapsulated by molding compounds. In some embodiments, the carrier10may include, for example, a printed circuit board (PCB), such as a paper-based copper foil laminate, a composite copper foil laminate, or a polymer-impregnated glass-fiber-based copper foil laminate. In some embodiments, the carrier10may include a semiconductor substrate including silicon, germanium, or other suitable materials. In some embodiments, the carrier10may include a redistribution layer (RDL) (not shown) including a plurality of conductive traces and/or a plurality of conductive vias.

The lid11may be disposed over the carrier10. The lid may include a portion11aextending substantially perpendicular to the upper surface101of the carrier10and a portion11bextending substantially perpendicular to the portion11a. The portion11amay connect with the portion11b. The adhesive layer12may connect the portion11bof the lid11and the carrier10(e.g., the upper surface101of the carrier10). The adhesive layer12may include silicone, wax, polymer, metal, or other suitable materials. The lid11may have an opening (or a window or hole)11h. The opening11hmay be defined by opposite sides11b1and11b2of the portion11b. The cavity C1may connect with the opening11h. The opening11hmay be located over the cavity C1. The opening11hmay be located over the optical component13. A portion of the optical component13may be exposed by the opening11h.

The optical component (or a photonic component)13may be disposed over the carrier10(or the upper surface101of the carrier10). The optical component13may be disposed below the lid11. The optical component13may be surrounded by the lid11. The optical component13may be disposed within the cavity C1. The optical component13may have an upper surface131facing the lid11and a lower surface132facing the carrier10. The upper surface131is opposite to the lower surface132. The lower surface132of the optical component13may be in contact with the upper surface101of the carrier through an adhesive layer13a. The optical component13may include a photonic integrated circuit. The optical component13may be configured to transmit or receive one or more optical signals. The optical component13may be configured to transmit or receive one or more electrical signals. The optical component13may be configured to convert optical signals to electrical signals and vice versa.

The optical component13may include pads13p1and13p2at the upper surface131of the optical component13. The pads13p1and13p2may be electrically connected to a circuit structure (not shown) in the optical component13. The optical package device100may include a plurality of wires13w1and13w2respectively connecting the pads13p1and13p2of the optical component13to the carrier10(e.g., a plurality of pads10clat the upper surface101of the carrier10). The wires13w1and the13w2may be disposed at opposite sides of the optical component13. The wires13w1and/or wires13w2may electrically connect the optical component13to the carrier10.

FIG.1Ais a perspective view of an optical package device (e.g., the optical package device100A) in accordance with some embodiments of the present disclosure.

Referring toFIGS.1and1A, the optical component13may include an optical source14, a waveguide (or a channel)15, and an optical phase array (or a phase change element)16. The optical source14may be optically coupled to the waveguide15. The optical phase array16may be optically coupled to the waveguide15. In some embodiments, the optical package device100A may include the optical source14, the waveguide15, and the optical phase array16.

The optical source14may be disposed at the upper surface131of the optical component13. The optical source14may be disposed over the optical component13. The optical source14may be partially embedded in the optical component13. The optical source14may include a portion embedded in the optical component13. The optical source14may have a surface142between the surface131and the surface132of the optical component13. The optical source14may have an end14eoptically coupled to the waveguide15. The optical source may be configured to generate an input optical signal (or an optical signal) L20as illustrated inFIG.1A. The optical source14may be configured to generate the input optical signal L20based on the electrical signals transmitted from the circuit structure of the optical component13or the wires13w1and13w2.

The optical source14may include a coherent optical source. The optical source14may be configured to emit coherent light. The optical source14may include, for example, a laser. The optical source14may include, for example, an edge-emitting layer configured to couple the waveguide15at the end14eof the optical source14. In some embodiments, the optical source14may include, for example, a vertical cavity surface emitting layer (VCSEL), such that the optical source14may emit the input optical signal L20at the lower surface142. The input optical signal L20may be generated by the coherent optical source140with a fixed wavelength that operably communicates with the waveguide15.

As shown inFIG.1, the waveguide15may be disposed between the optical source14and the optical phase array16. As shown inFIG.1A, the waveguide15may be configured to transmit the input output signal L20. The waveguide15may include a portion (or a first portion)151optically coupled to the optical source14and a portion152(or a second portion)152optically coupled with the optical phase array16. The portion151may be connected to the portion152. The portion151may include a Y-branch waveguide that splits the input optical signal L20into a plurality of sub-beams. The portion152may include a plurality of Y-branch waveguides that receive the sub-beams from the portion151and split them into a plurality of sub-beams SB11, SB12, SB13, . . . , SB1M, wherein M can be an integer. The waveguide15as illustrated inFIG.1Ais an example only. The waveguide15may include more portions than portions151and152. The waveguide15may include other types of splitters; for example, a directional splitter, a multimode interference splitter, or the like. In some embodiments, the waveguide15may be configured to transmit the sub-beams SB11, SB12, SB13, . . . , SB1M. The waveguide15may be made of dielectric material or any other optically conductive materials.

As shown inFIG.1, the optical phase array16may be disposed within the optical component13. The optical phase array16may be disposed at the upper surface131of the optical component13. In some embodiments, the optical phase array16may be disposed on the optical component13. The optical phase array16may be exposed by the opening11hof the lid11. As shown inFIG.1A, the optical phase array16may include a plurality of unit cells161,162,163, . . . ,16M. The unit cells161,162,163, . . . ,16M may be optically coupled to portion152of the waveguide15. Each of the unit cells161,162,163, . . . ,16M may be configured to respectively receive the sub-beams SB11, SB12, SB13, . . . , SB1M. Each of the unit cells may allow a sub-beam to propagate therethrough. The optical phase array16as illustrated inFIG.1Ais an example only. The optical phase array16may include 64*64 unit cells in an array or another configuration.

Each of the unit cells161,162,163, . . . ,16M may include a phase shifter161pand a radiator (or an antenna element, or a grating portion)161r. Each of the phase shifters161pmay be configured to alter (or adjust, control) the phase of the corresponding sub-beam (one of the sub-beams SB11, SB12, SB13, . . . , SB1M) of the input output signal L20. In some embodiments, the phase shifters161pmay be configured to induce a thermo-optic phase shift on the phase of the sub-beams SB11, SB12, SB13, . . . , SB1M. The phase shifters161pmay be thermo-optic phase shifters. The phase shifters161pmay be configured to induce an electro-optic phase shift on the phase of the sub-beams SB11, SB12, SB13, . . . , SB1M. The phase shifters161pmay be electro-optic phase shifters. In some embodiments, the phase shifters161pmay adjust the refractive indexes of the unit cells (e.g., waveguides).

The radiators161rmay be configured to the sub-beams SB11, SB12, SB13, . . . , SB1M from the input output signal L20. In some embodiments, the radiators161rmay be configured to output a plurality of wavefronts based on the sub-beams SB11, SB12, SB13, . . . , SB1M. The wavefronts may interfere with each other through multiple slit diffraction. In some embodiments, the sub-beams SB11, SB12, SB13, . . . , SB1M generated by the optical phase array16may form a beam (or a first beam) L1through multiple slit diffraction. By adjusting or controlling the phase of the sub-beams SB11, SB12, SB13, . . . , SB1M of the input output signal L20, the direction or intensity of the beam L1can be adjusted or controlled. In other words, by dynamically controlling the optical properties of the sub-beams SB11, SB12, SB13, . . . , SB1M of the input output signal L20, the optical phase array16(or the optical component13) may be configured to steer the direction of the beam L1. In some embodiments, the optical phase array16may be configured to alter a wavefront of the input optical signal L20. The beam L1may be deflected from a propagation direction of the input optical signal L20.

The optical component13may be configured to change a phase of the input optical signal L20from a first state to a second state and to output the beam L1with a phase of the second state. In particular, the optical phase array16may be configured to change the phase of the input optical signal L20from the first state to the second state by the phase shifters161pand output the beam L1with the phase of the second state in response to the input optical signal L20through multiple slit diffraction.

Referring again toFIG.1, the optical phase array16may steer the beam L1by controlling the phase of the sub-beams SB11, SB12, SB13, . . . , SB1M of the input optical signal L20. The optical phase array16may be configured to consecutively adjust the direction of the beam L1. The beam L1may be emitted by the optical phase array16in different directions at respective time intervals. The optical phase array16may be configured to output the beam L1in a scanning manner. The beam L1may propagate through the opening11h. In other words, the optical phase array16may be configured to scan an external object through the beam L1. As shown inFIG.1, the beam L1may have a scanning movement SN1to define a scanning angle SA1. The scanning angle SA1may be around 100, 120, or 140 degree. The scanning angle SA1may be controlled by the optical phase array16, such that the beam L1in different directions may pass through the opening11hbut not reach the sides11b1and11b2of the portion11bof the lid11.FIGS.1B and1Cmay illustrate one or more operations of the optical phase array16.

FIG.1Bis a schematic diagram of the operation of an optical phase array (e.g., the optical phase array16) in accordance with some embodiments of the present disclosure.FIG.1Cis a schematic diagram of the operation of an optical phase array (e.g., the optical phase array16) in accordance with some embodiments of the present disclosure.

Referring toFIG.1B, the beam L1may project a pattern FL on the object OB1outside or adjacent to the optical package device100A via the beam L1. The pattern FL may include a flood light or be analogous to flood light. The optical phase array16may be configured to scan an object OB1via the beam L1. The beam L1may continuously change its direction by controlling the optical phase array16, and may arrive at different portions of the object OB1. The speed of the change of the direction of the beam L1may be higher than a detection refresh speed. The cone size of the beam L1over the object OB1may be less than 1 degree.

Referring toFIG.1C, the beam L1may project a pattern DP on the object OB1outside or adjacent to the optical package device100A via a beam L1′. The pattern DP may include a plurality of dots (or a dot array) over the object OB1or be analogous to a dot array. The dots of the pattern DP may be separated from each other. The beam L1′ may have optical properties similar to the beam L1, except that the extent of the change of the direction of the beam L1′ may be greater than that of the beam L1, or the cone sizes of the beams L1and L1′ may be different.

In some embodiments, the optical source14may include a plurality of optical sources respectively generate input optical signals for projecting the pattern FL and the pattern DP, respectively.

Referring again toFIG.1, a physical axis13cof the optical component13perpendicular thereto may be misaligned with a physical axis11hcof the opening11h. A physical axis16cof the optical phase array16perpendicular thereto may be substantially aligned with the physical axis11hcof the opening11h. The optical phase array may be disposed offset from the physical axis13cof the optical component13. An optical axis L1aof the beam L1may be substantially parallel to the physical axis11hcof the opening11h. The optical axis L1aof the beam L1may be substantially aligned with the physical axis11hcof the opening11h. Therefore, the beam L1can propagate through the opening11hwithout striking the portion11bof the lid11.

In some comparative embodiments, an optical package device may include a stack of lenses and optical components to project a particular pattern (e.g., the flood light, or the dot array), and the sizes (e.g., the Z-height) of said lenses and components may not allow them to fit onto the optical package device given the trend of ever-shrinking parts in semiconductor manufacturing. Furthermore, a significant number of the alignment steps is required for the numerous optical components and a package body (e.g., a lid). The offset or misalignment occurring in the alignment steps would cause an unacceptable amount of error to accumulate. In the present disclosure, the optical phase array16disposed within the lid11may be configured to output the beam L1in the scanning manner to project the patterns FL and/or DP on the object OB1without the existence of numerous lenses or optical guiding elements. As such, the size (e.g., Z-height) of the optical package device100A can be reduced. During the manufacture of the optical package device100A, the alignment steps may be significantly reduced, e.g., to only 2 alignment steps, which will be discussed inFIGS.3A-3D. The offset or misalignment can be significantly reduced.

FIG.1Dis a cross-sectional view of an optical package device (e.g., an optical package device100B) in accordance with some embodiments of the present disclosure. Some detailed descriptions may correspond to preceding paragraphs related toFIGS.1and1Aand are not repeated hereinafter for conciseness, with differences therebetween as follows.

The optical package device100B may include an electronic component20disposed adjacent to the optical component13. The electronic component20may be disposed outside the cavity C1. The electronic component20may include a pad20p1at an upper surface of the electronic component20. The pad20p1may be electrically connected to a circuit structure (not shown) in the electronic component20. The optical package device100may include a wire20w1connecting the pad20p1of the electronic component20to the carrier10(e.g., the pad10clat the upper surface101of the carrier10). The wire20w1may electrically connect the electronic component20to the carrier10. The electronic component20may be electrically connected to the optical component13through the carrier10. The electronic component20may be configured to control the optical source14and the optical phase array16of the optical component13.

In an alternative embodiments, the optical component13may include the electronic component20ofFIG.1D. The electronic component20may be disposed over the surface131of the optical component13and adjacent to the optical source14.

FIG.1Eis a cross-sectional view of an optical package device (e.g., an optical package device100C) in accordance with some embodiments of the present disclosure. Some detailed descriptions may correspond to preceding paragraphs related toFIGS.1and1Aand are not repeated hereinafter for conciseness, with differences therebetween as follows.

The lid11may be angled in relation to the carrier10. The portion11aof lid11may be angled in relation to the upper surface101of the carrier10. During the attachment process of the lid11to the carrier10, the lid11may be tilted and placed on the upper surface101of the carrier10. As such, the physical axis16cof the optical phase array16perpendicular thereto and the physical axis11hcof the opening11hmay form an angle θ1. The angle θ1may be around 0.5, 1, 2, 3 degrees or more. Therefore, the optical phase array16may not directly align with the opening11h. In other words, the physical axis16cof the optical phase array16is misaligned with the physical axis11hcof the opening11h.

Advantageously, the optical package device100C is able to actively adjust the direction of the beam L1. By altering (or adjusting, controlling) the phase of the sub-beams SB11, SB12, SB13, . . . , SB1M of the input output signal L20, the multiple slit diffraction occurs between the wavefronts of the sub-beams SB11, SB12, SB13, . . . , SB1M may output the beam L1with a tilted optical axis L1a′, with respect to the optical phase array16. The optical axis L1a′ of the beam and the physical axis16cof the optical phase array16may form the angle θ1. The optical axis L1a′ of the beam L1may be substantially parallel to the physical axis11hcof the opening. As such, the beam L1can propagate through the opening11hwithout striking the portion11bof the lid11. That is, an offset (including shift or tilt) between the opening11hand the optical phase array16that occurs during the attachment process can be compensated by actively steering the beam L1to a desired direction.

FIG.2is a cross-sectional view of an optical package device (e.g., an optical package device200) in accordance with some embodiments of the present disclosure. Some detailed descriptions may correspond to preceding paragraphs related toFIGS.1and1Aand are not repeated hereinafter for conciseness, with differences therebetween as follows.

The optical package device200may further include an optical guiding component17disposed over the portion11bof the lid11. The optical guiding component17may be attached to the portion11bof the lid11via a connection element18. The optical guiding component17may cover the opening11h. In some embodiments, a physical axis17cmay be aligned with the physical axis11hcof the opening11h. The optical guiding component17may be disposed adjacent to the optical component13. The optical guiding component17may be aligned with the optical phase array16. In some embodiments, the physical axis17cmay be aligned with the physical axis16cof the optical phase array16. In some embodiments, the optical guiding component17may vertically overlap the grating portion161rof the optical phase array16.

The optical phase array16may be configured to output a beam (or a second beam) L2. The beam L2may propagate from the optical phase array16to the optical guiding component17. The beam L2may have a cone angle less than 1 degree. The optical phase array16may be configured to steer the beam L2by controlling the phase of the sub-beams SB11, SB12, SB13, . . . , SB1M of the input optical signal L20. The optical phase array16may be configured to output the beam L2in a scanning manner (similar to the beam L1ofFIG.1) and allow the beam L2to pass through the optical guiding component17. The optical guiding component17may be configured to diffract the beam L2. The diffracted beam L2from the optical guiding component17may project a pattern (e.g., the flood light FL or the dot array DP as shown inFIGS.1B and1C) on an external object.

In the present disclosure, the optical phase array16and the optical guiding component17may be configured to collectively output the diffracted beam L2to project a pattern on an external object without the existence of a stack of lenses and optical components. As such, the size (e.g., Z-height) of the optical package device200can be reduced. During the manufacture of the optical package device200, the alignment steps may be significantly reduced, e.g., to only 3 alignment steps, which will be discussed inFIGS.3A-3F. The offset or misalignment can be significantly reduced.

The optical guiding component17may be electrically isolated. In some embodiments, the optical guiding component17may include a MEMS structure, a micro-lens array (MLA), or a diffraction optical element (DOE).

FIG.2Ais a cross-sectional view of an optical package device (e.g., an optical package device200A) in accordance with some embodiments of the present disclosure. Some detailed descriptions may correspond to preceding paragraphs related toFIG.2and are not repeated hereinafter for conciseness, with differences therebetween as follows.

The optical guiding component17may be angled in relation to the lid11. The optical guiding component17may be angled in relation to the portion11bof lid11. During the attachment process of the optical guiding component17to the lid11, the lid11may be tilted and placed on the portion11bof lid11. As such, the physical axis16cof the optical phase array16perpendicular thereto is not parallel with a physical axis17cof the optical guiding component17perpendicular thereto. In some embodiments, the physical axis13cof the optical component13perpendicular thereto is not parallel with a physical axis17cof the optical guiding component17perpendicular thereto. The physical axis16cof the optical phase array16perpendicular thereto and the physical axis17cof the optical guiding component17may form an angle θ2. The angle θ2may be around 0.5, 1, 2, 3 degrees or more. Therefore, the optical phase array16may not directly align with the optical guiding component17. In other words, the physical axis16cof the optical phase array16is misaligned with the physical axis17cof the optical guiding component17.

Advantageously, the optical package device200A is able to actively adjust the direction of the beam L2. By altering (or adjusting, controlling) the phase of the sub-beams SB11, SB12, SB13, . . . , SB1M of the input output signal L20, the multiple slit diffraction occurs between the wavefronts of the sub-beams SB11, SB12, SB13, . . . , SB1M may output the beam L2with a tilted optical axis L2a′, with respect to the optical phase array16. The optical axis L2a′ of the beam L2and the physical axis16cof the optical phase array16(or the physical axis13cof the optical component13) may form an angle θ2. The optical axis L2a′ of the beam L2may be substantially parallel to the physical axis17cof the optical guiding component17. As such, the beam L2can propagate toward the optical guiding component17and be incident on the optical guiding component17at a desired angle (e.g., normal angle). That is, an offset (including shift or tilt) between the optical guiding component17and the optical phase array16that occurs during the attachment process can be compensated by actively steering the beam L2to a desired direction.

In some embodiments, the optical component13may include the electronic component20ofFIG.1D. In some embodiments, the electronic component20may be disposed over the surface131of the optical component13and adjacent to the optical source14. The electronic component20may include a processing unit configured to calculate an optimal incident area on the optical guiding component17for the beam L2to pass through. The optimal incident area may be defined as available optical power output behind component17. The electronic component in the optical component13may include a storage unit configured to store the optimal incident area. In some embodiments, the optical component13may include an electronic component or an integrated circuit (not shown) configured to perform a function which is the same as or similar to that of the electronic component20.

FIG.2Bis a cross-sectional view of an optical package device (e.g., an optical package device200B) in accordance with some embodiments of the present disclosure. Some detailed descriptions may correspond to preceding paragraphs related toFIG.2and are not repeated hereinafter for conciseness, with differences therebetween as follows.

The lid11may be angled in relation to the carrier10. The portion11aof lid11may be angled in relation to the upper surface101of the carrier10. During the attachment process of the lid11to the carrier10, the lid11may be tilted and placed on the upper surface101of the carrier10. As such, the physical axis16cof the optical phase array16perpendicular thereto and the physical axis17cof the optical guiding component17may form an angle θ3. The angle θ3may be around 0.5, 1, 2, 3 degrees or more. Therefore, the optical phase array16may not directly align with the optical guiding component17. In other words, the physical axis16cof the optical phase array16is misaligned with the physical axis17cof the optical guiding component17.

Advantageously, the optical package device200B is able to actively adjust the direction of the beam L2. By altering (or adjusting, controlling) the phase of the sub-beams SB11, SB12, SB13, . . . , SB1M of the input output signal L20, the multiple slit diffraction occurs between the wavefronts of the sub-beams SB11, SB12, SB13, . . . , SB1M may output the beam L2with a tilted optical axis L2a′, with respect to the optical phase array16. The optical axis L2a′ of the beam L2and the physical axis16cof the optical phase array16may form the angle θ3. The optical axis L2a′ of the beam L2may be substantially parallel to the physical axis17cof the optical guiding component17. As such, the beam L2can propagate toward the optical guiding component17and be incident on the optical guiding component17at a desired angle (e.g., normal angle). That is, an offset (including shift or tilt) between the optical guiding component17and the optical phase array16that occurs during the attachment process can be compensated by actively steering the beam L2to a desired direction.

FIG.2Cis a cross-sectional view of an optical package device (e.g., an optical package device200C) in accordance with some embodiments of the present disclosure. Some detailed descriptions may correspond to preceding paragraphs related toFIG.2and are not repeated hereinafter for conciseness, with differences therebetween as follows.

The attachment of the lid11to the carrier10may have an offset or error. Owing to the offset or error, the physical axis17cof the optical guiding component17is shifted from the physical axis16cof the optical phase array16with an offset OS1. The offset OS1may be around 50, 100, 150, 200, 250 μm. The physical axis17cof the optical guiding component17may be misaligned with the physical axis16cof the optical phase array16.

Advantageously, the optical package device200C is able to actively adjust the direction of the beam L2. By altering (or adjusting, controlling) the phase of the sub-beams SB11, SB12, SB13, . . . , SB1M of the input output signal L20, the multiple slit diffraction occurs between the wavefronts of the sub-beams SB11, SB12, SB13, . . . , SB1M may output the beam L2with a tilted optical axis L2a′, with respect to the optical phase array16. The beam L2can propagate toward the optical guiding component17and be incident on the optical guiding component17at a desired angle (e.g., normal angle). That is, an offset (including shift or tilt) between the optical guiding component17and the optical phase array16that occurs during the attachment process can be compensated by actively steering the beam L2to a desired direction.

FIGS.3A,3B,3C, and3Dshow one or more stages of an exemplary method for manufacturing an optical package device (e.g., the optical package device100A,100B, or100C) according to some embodiments of the present disclosure.FIGS.3A,3B,3C,3D,3E, and3Fshow one or more stages of an exemplary method for manufacturing an optical package device (e.g., the optical package device200,200A,200B, or200C) according to some embodiments of the present disclosure.

As shown inFIG.3A, an optical component13may be provided. The optical component13may include a plurality of pads13p1and13p2, a waveguide15, and an optical phase array16. The optical component13may have a lower surface (or a surface)132and an upper surface (or a surface)131opposite to the lower surface132. The plurality of pads13p1and13p2may be disposed at the upper surface131. The waveguide15may be disposed adjacent to the upper surface131. The optical phase array may have a surface1601coplanar with the upper surface131. The optical component13may have a recess13rat the upper surface131. The recess13rmay have a lateral surface13r3. An optical source14may be disposed over the optical component13through a first alignment AN1. The first alignment AN1may have a passive alignment.

As shown inFIG.3B, the optical source14may be disposed into the recess13r. The optical source14may be partially embedded in the optical component13. The optical source14may have an end14ein contact with the lateral surface13r3of the recess13r. The waveguide15may be optically coupled to the optical source14and the optical phase array16.

The optical component13may be attached to a carrier10via an adhesive layer13a. The carrier10may have an upper surface101and a lower surface102opposite to the upper surface101. The carrier10may include a plurality of pads10cat the lower surface102and a plurality of pads10clat the upper surface101.

As shown inFIG.3C, a plurality of wires13w1and13w2are formed to electrically connect the optical component13and the carrier10prior to attaching a lid11to the carrier10.

As shown inFIG.3D, the lid11is attached to the carrier10through a second alignment AN2to surround the optical component13to form an optical package device, e.g., the optical package device100A. The lid11may have a portion11aand a portion11bconnected to the portion11a. The attachment of the lid may include attaching the portion11aof the lid11to the upper surface b101of the carrier10. The portion11bmay have an opening11h. The second alignment AN2allows the opening11hto be substantially aligned with the optical phase array16. The second alignment AN2may have a passive alignment and an active alignment. The optical phase array16may be configured to output a beam to alignment equipment. Based on the beam from the optical phase array16, the attachment of the lid11can be more accurate.

As shown inFIG.3E, a cavity C1may be defined by the lid11and the carrier10. The cavity C1may accommodate the optical component13.

As shown inFIG.3F, an optical guiding component17is attached to the lid11through a third alignment AN3to form an optical package device, e.g., the optical package device200. The optical guiding component may be attached to the lid11via a connection element18. The third alignment AN3allows the opening11hto be substantially aligned with the optical guiding component17. The third alignment AN3may have a passive alignment and an active alignment. The optical phase array16may be configured to output a beam to the optical guiding component17, which in turn outputs the other beam to alignment equipment. Based on the beam from the optical guiding component17, the attachment of the optical guiding component17can be more accurate.

FIG.4is a cross-sectional view of an optical package device (e.g., an optical package device300) in accordance with some embodiments of the present disclosure.FIG.4Ais a perspective view of an optical package device (e.g., an optical package device300) in accordance with some embodiments of the present disclosure. The optical package device300ofFIGS.4and4Ais similar to the optical package device100A of theFIGS.1and1A. Some detailed descriptions may correspond to preceding paragraphs related toFIGS.1and1Aand are not repeated hereinafter for conciseness, with differences therebetween as follows.

The optical package device300may further include an optical guiding component27disposed within the opening11hof the lid11. The optical guiding component27may be attached to the sides11b1and11b2of the portion11bof the lid11via a connection element28. A physical axis27cof the optical guiding component27perpendicular thereto may be aligned with the physical axis16cof the optical phase array16. The physical axis27cof the optical guiding component27perpendicular thereto may be misaligned with the physical axis13cof the optical component13.

The optical component13may further include a sensing region19adjacent to the optical phase array16. The sensing region19may include a plurality of detectors191and192adjacent to the surface1601of the optical phase array16. Each of the detectors192may be disposed between two unit cells (e.g., the unit cells161and162) of the optical phase array16. The detector191may be disposed between the radiators161rand the pad13p2.

In some embodiments, the optical guiding component27may vertically overlap the grating portion161rof the optical phase array16. In some embodiments, the optical guiding component27may vertically overlap the sensing portion19of the optical phase array16.

The optical phase array16may be configured to output a beam L3. An optical axis L3aof the beam L3may be aligned with the physical axis27cof the optical guiding component27. The beam L3may propagate from the optical phase array16to the optical guiding component27. The beam L3may have a cone angle less than 1 degree. The optical phase array16may be configured to steer the beam L3by controlling the phase of the sub-beams SB11, SB12, SB13, . . . , SB1M of the input optical signal L20. The optical phase array16may be configured to output the beam L3in a scanning manner (similar to the beam L1ofFIG.1). The optical guiding component17may be configured to reflect the beam L3to be beams L41and L42. The reflected beams L41and L42from the optical guiding component27may be detected by the sensing region19of the optical component13. The optical guiding component27may be configured to detect an external signal, e.g., an audio signal. The optical guiding component27may include a membrane.

The reflected beams L41and L42may carry the information associated with the external signal. Based on the beam L3and the reflected beams L41and L42, the optical component13may be configured to determine the external signal. In some embodiments, the optical component13may include an electronic component or an integrated circuit configured to determine the external signal.

FIG.5is a cross-sectional view of an optical package device (e.g., an optical package device300A) in accordance with some embodiments of the present disclosure. Some detailed descriptions may correspond to preceding paragraphs related toFIGS.4and4Aand are not repeated hereinafter for conciseness, with differences therebetween as follows.

The lid11may be angled in relation to the carrier10. The portion11aof lid11may be angled in relation to the upper surface101of the carrier10. During the attachment process of the lid11to the carrier10, the lid11may be tilted and placed on the upper surface101of the carrier10. As such, the physical axis16cof the optical phase array16perpendicular thereto and the physical axis27cof the optical guiding component27may form an angle θ4. The angle θ4may be around 0.5, 1, 2, 3 degrees or more. Therefore, the optical phase array16may not directly align with the optical guiding component27. In other words, the physical axis16cof the optical phase array16is misaligned with the physical axis27cof the optical guiding component27.

Advantageously, the optical package device300A is able to actively adjust the direction of the beam L3. By altering (or adjusting, controlling) the phase of the sub-beams SB11, SB12, SB13, . . . , SB1M of the input output signal L20, the multiple slit diffraction occurs between the wavefronts of the sub-beams SB11, SB12, SB13, . . . , SB1M may output the beam L3with a tilted optical axis L3a′, with respect to the optical phase array16. The optical axis L3a′ of the beam L3and the physical axis16cof the optical phase array16may form an angle θ4. The optical axis L3a′ of the beam L3may be substantially parallel to the physical axis27cof the optical guiding component27. As such, the beam L3can propagate toward the optical guiding component27and be incident on the optical guiding component27at a desired angle (e.g., normal angle). That is, an offset (including shift or tilt) between the optical guiding component27and the optical phase array16that occurs during the attachment process can be compensated by actively steering the beam L3to a desired direction.

FIGS.6A,6B,6C,6D,6E, and6Fshow one or more stages of an exemplary method for manufacturing an optical package device (e.g., the optical package device300or300A) according to some embodiments of the present disclosure.

The stages as illustrated inFIGS.6A-6Eare similar to those inFIGS.3A-3E, respectively, except that the optical component13may further include a plurality of detectors191and192.

As shown inFIG.6F, an optical guiding component27is attached to the lid11to form an optical package device, e.g., the optical package device300. The optical guiding component27may be disposed within the opening11hvia a connection element28. The optical guiding component27may be substantially aligned with the optical phase array16.