System and method for transferring optical signals in photonic devices and method of making the system

Embodiments of the disclosure pertain to a system for transferring an optical signal from one photonics chip or integrated circuit (PIC) to another. The system includes a first PIC having (i) an optical emitter or optical transmission mechanism and (ii) a focusing mirror thereon, and a second PIC having an optical receiver and a reflecting mirror thereon. The reflecting mirror is configured to reflect light transmitted by the optical emitter or optical transmission mechanism back to the first PIC. The focusing mirror is configured to (i) further reflect the light reflected by the reflecting mirror and (ii) focus the further reflected light on the optical receiver. Methods of using and manufacturing the system are also disclosed.

CROSS REFERENCE TO RELATED APPLICATION

This application is a national phase application of PCT Application No. PCT/US19/23547, filed on Mar. 22, 2019, incorporated herein by reference as if fully set forth herein.

FIELD OF THE INVENTION

The present invention relates to the field of optical or optoelectronic transmitters, and particularly to optical modulators configured to modulate a continuous light beam to be output as an optical signal by an optical or optoelectronic transmitter.

DISCUSSION OF THE BACKGROUND

Optical or optoelectronic transceivers (which may be generally identified as “optical transceivers”) convert electrical signals into optical signals and optical signals into electrical signals. An optical transceiver may include receiver and transmitter optical subassemblies, functional circuits, and electrical and optical interfaces, and are significant components in optical fiber communication systems and data storage networks.

In general, photonics is a field relating to light (photon) generation, detection, and manipulation through emission, transmission, modulation, signal processing, switching, amplification, and/or sensing. One goal of photonics is to use light to perform functions that traditionally fall within the domain of electronics, such as telecommunications, information processing, etc. Thus, photonic applications use photons in largely the same way that electronic applications use electrons.

Devices that use light as an information carrier have a number of advantages over those that use electricity. For example, light may travel at a speed that is about an order of magnitude (e.g., about 10 times) greater than the typical speed of electricity, which means (among other things) that data transmitted photonically can travel long distances in a fraction of the time that electrical signals need to travel the same distance. Furthermore, unlike electric currents, light beams in various bands (e.g., visible light and infrared [IR] light) pass through each other without interacting, so they do not interfere with each other. For example, a single optical fiber has the capability to carry up to three million telephone calls simultaneously.

However, coupling light between two optical chips can be challenging. For example, waveguides on silicon photonics chips and laser chips typically have micron or submicron minimum or correctional dimensions. On the other hand, the mode size or beam width of light emerging from conventional waveguides is a few microns in diameter. Thus, misalignment of light passing from one optical chip to another can be a challenging problem to solve.

In the field of photonics, a “1 dB alignment tolerance” is the maximum misalignment that keeps the coupling efficiency between the two chips (or between a chip and another structure, such as an optical fiber) within 1 dB of the peak efficiency. Typically, the 1 dB alignment tolerance between two photonic devices is only 1-2 microns (μm). Active alignment of the photonic devices can ensure compliance with a specification requiring a certain 1 dB alignment tolerance.

“Active alignment” refers to a process in which one or more devices are temporarily held in place (e.g., with a clamp or uncured adhesive) while one or more other devices are either fixed or temporarily held in place, a measurement is made of the amount of light transmitted from an origin to a target, one of the temporarily-held devices is repositioned, the measurement is made again, and an improvement or deterioration in the alignment of the devices is determined. The process is repeated until a desired or threshold level of confidence in the positions of the devices corresponding to the best measurement(s) is achieved, and the devices are then permanently fixed in those positions.

However, active alignment of photonic devices typically requires tools and procedures that may be relatively complicated and/or that may be less than ideal. Thus, active alignment of photonic devices can have a relatively high cost and/or a relatively low throughput.

FIG. 1shows a cross-section of a conventional chip-to-chip coupling scheme100, in which a first photonic device (e.g., a laser or laser diode chip)110emits or transmits light125ato a second photonic device (e.g., a waveguide or light processing chip)140. The light125amay be emitted from or transmitted through a light output mechanism120. The light output mechanism120may be or include a laser diode or a grating coupler (which may receive the light from a waveguide in the first photonic device110). The light125ais focused by a lens130. The focused light125bis received by a light receiving mechanism150. The light receiving mechanism150may be or include a second grating coupler, a mirror or other reflective surface, or a photodiode.

However, problems exist in the scheme100. For example, a small change in the position of the lens can have a relatively large effect on the location of the focal point of the focused light125b. For example,FIG. 2shows a cross-section of a chip-to-chip coupling system200, including a light transmitting chip210and a light receiving chip240. The light transmitting chip210transmits a light beam215from a grating coupler or emitter220. The emitted light passes through a lens230, and the focused light235is received by a grating coupler or detector250in the light receiving chip240. The light transmitting chip210and the light receiving chip240are spaced apart by a distance D.

FIG. 3Ashows a cross-section of a model300for the system200, including a light emitter310, a spherical focusing lens320, and a light detector330. The light emitter310and the light detector330are separated by a distance D of 200 μm. Each of the light emitter310and the light detector330have a round shape in a plan (or top-down) view, with a diameter of 9.2 μm. The lens320has a diameter of 43 μm.

FIG. 3Bis a graph350showing the coupling tolerance of the light emitter310and the light detector330through the lens320. The curve360is the coupling loss (in dB) of the system300as a function of misalignment of the light detector330in either the x direction or the z direction (in μm). The dashed lines370a-bshow that the simulated 1 dB alignment tolerance of the model300(FIG. 3A) is 2.3 microns (μm).

This “Discussion of the Background” section is provided for background information only. The statements in this “Discussion of the Background” are not an admission that the subject matter disclosed in this “Discussion of the Background” section constitutes prior art to the present disclosure, and no part of this “Discussion of the Background” section may be used as an admission that any part of this application, including this “Discussion of the Background” section, constitutes prior art to the present disclosure.

SUMMARY OF THE INVENTION

In one aspect, the present invention relates to a system, comprising a first photonics chip or integrated circuit (IC) having an optical emitter or optical transmission mechanism thereon, a second photonics chip or IC having an optical receiver thereon, a reflecting mirror on the second photonics chip or IC, and a focusing mirror on the first photonics chip or IC. The reflecting mirror is configured to reflect light transmitted by the optical emitter or optical transmission mechanism back to the first photonics chip or IC. The focusing mirror is configured to (i) further reflect the light reflected by the reflecting mirror and (ii) focus the further reflected light on the optical receiver.

In some embodiments, the optical emitter or optical transmission mechanism comprises the optical emitter. The optical emitter may comprise a laser diode.

In other embodiments, the optical emitter or optical transmission mechanism comprises the optical transmission mechanism. The optical transmission mechanism may comprise a first grating coupler or a first reflective surface. In such embodiments, the system further may comprise a first waveguide in the first photonics chip or IC. The first waveguide may be (i) configured to carry the optical signal and/or (ii) optically coupled to the grating coupler or the reflective surface.

In some embodiments, the optical receiver comprises a photodiode. Alternatively, the optical receiver may comprise a second grating coupler or a second reflective surface. When the optical receiver comprises a grating coupler or reflective surface, the system may further comprise a second waveguide in the second photonics chip or IC. The second waveguide may be (i) optically coupled to the second grating coupler or the second reflective surface and/or (ii) configured to carry the optical signal (e.g., in the second photonics chip or IC).

In other or further embodiments, the focusing mirror and/or the reflecting mirror may comprise a concave depression or indentation in the respective first or second photonics chip or IC. Alternatively, the focusing mirror and/or the reflecting mirror may comprise (i) a planar reflecting surface on the respective first or second photonics chip or IC and (ii) a lens on or above the planar reflecting surface. When the lens is above the planar reflecting surface, the focusing mirror and/or the reflecting mirror further comprise a physical support structure integrated with and/or connected to the lens and the respective first or second photonics chip or IC.

In another aspect, the present invention relates to a method of transferring light, comprising emitting or transmitting light from an optical emitter or optical transmission mechanism on a first photonics chip or IC, reflecting the light back to the first photonics chip or IC using a reflecting mirror on a second photonics chip or IC, further reflecting the light to and focusing the reflected light on a light receiver on the second photonics chip or IC using a focusing mirror on the first photonics chip or IC, and receiving the further reflected and focused light at the optical receiver. In some embodiments, the light is emitted or transmitted from the optical emitter or optical transmission mechanism to the reflecting mirror, and/or the reflecting mirror reflects the light to the focusing mirror.

In some embodiments, the light is transmitted by the optical transmission mechanism, and the method may further comprise carrying the light in a first waveguide in the first photonics chip or IC before transmitting the light from the optical transmission mechanism. Similarly, in other or further embodiments, the method may further comprise carrying the light in a second waveguide in the second photonics chip or IC after receiving the light at the optical receiver.

In yet another aspect, the present invention relates to a method of manufacturing a light transfer system, comprising forming or making an optical emitter or transmission mechanism and a focusing mirror on a first photonics chip or IC, forming or making a light receiver and a reflecting mirror on a second photonics chip or IC, and positioning the first photonics chip or IC and the second photonics chip or IC such that light emitted or transmitted by the optical emitter or transmission mechanism is (i) reflected by the reflecting mirror towards a first target on the first photonics chip or IC, (ii) further reflected and focused by the focusing mirror, and (iii) received by or at the light receiver.

In some embodiments, the first target is the focusing mirror, and/or the focusing mirror directs the light to the light receiver. In other or further embodiments, the method may further comprise forming a lens on or above at least one of the focusing mirror and the reflecting mirror.

Alternatively or additionally, the method may further comprise forming a waveguide in at least one of the first and second photonics chips or ICs. The waveguide may be optically coupled to (i) the optical transmission mechanism when the waveguide is formed in the first photonics chip or IC, or (ii) the optical receiver when the waveguide is formed in the second photonics chip or IC.

The present invention advantageously increases alignment tolerances or margin in chip-to-chip light transfers, generally by more than 5 times. The present system can reduce or cancel the impact of the misalignment parallel to the surfaces of the photonics chips/ICs, in many cases sufficiently to enable passive alignment (e.g., fixing the photonics chips/ICs in predetermined locations that have been previously determined empirically to result in alignment of the optical components on different chips). Relative to active alignment, passive alignment has a low cost and a high throughput.

Furthermore, all components can be integrated on either of the photonics chips, and can thus be fabricated with high accuracy and low cost. For example, the optical emitter/transmitter and the optical receiver can have the same design (e.g., the same polarization) and a well-matched mode profile, which can reduce or minimize mode mismatch and increase or maximize coupling efficiency. For example, most on-chip waveguides have a rectangular cross-section. As a result, the mode profile of on-chip waveguides approximates a rounded-corner rectangle. In addition, the polarization in on-chip waveguides is generally fixed, simplifying maintaining the polarization of the optical signal, reducing mode profile mismatch, and enabling high coupling efficiency. Finally, a mechanism that can eliminate a non-integrated lens in such device-to-device light transfers can simply the photonics system assembly process and/or reduce costs.

These and other features and advantages of the present invention will become readily apparent from the detailed description of various embodiments below.

DETAILED DESCRIPTION

For the sake of convenience and simplicity, the terms “transceiver,” “optical transceiver” and “optoelectronic transceiver” may be used interchangeably, as may the terms “optical” and “optoelectronic,” the terms “connected to,” “coupled with,” “coupled to,” and “in communication with” (which include both direct and indirect connections, couplings and communications), the terms “mounting,” “affixing,” “attaching” and “securing” (and grammatical variations thereof), and the terms “data” and “information,” but these terms are generally given their art-recognized meanings.

The term “length” generally refers to the largest dimension of a given 3-dimensional structure or feature. The term “width” generally refers to the second largest dimension of a given 3-dimensional structure or feature. The term “thickness” generally refers to a smallest dimension of a given 3-dimensional structure or feature. The length and the width, or the width and the thickness, may be the same in some cases (e.g., cylindrical structures such as optical fibers and certain other optical waveguides). A “major surface” refers to a surface defined by the two largest dimensions of a given structure or feature, which in the case of a structure or feature having a partially or completely circular or spherical surface, may be defined by the radius of the circle or sphere.

An Exemplary Chip-to-Chip Light Transfer System

FIG. 4shows an exemplary chip-to-chip light transfer system400including a first photonics chip or integrated circuit (IC)410and a second photonics chip or IC440. The first photonics chip or IC410comprises an optical emitter or transmitter420and a focusing mirror435, and the second photonics chip or IC420comprises an optical receiver or detector450and a reflecting mirror430. The first photonics chip or IC410is configured to emit or transmit a light beam422to the second photonics chip or IC420, and the second photonics chip or IC420is configured to receive a reflected, focused light beam426from the first photonics chip or IC410. The light beam422(which may comprise an optical signal carrying data and overhead or other information) is emitted or transmitted to the reflecting mirror430, which is configured to reflect the light beam (in the form of reflected light beam424) to the focusing mirror435. The focusing mirror435is configured to reflect and focus the reflected light beam (in the form of the reflected, focused light beam426) to the optical receiver or detector450.

Each of the first and second photonics chips or ICs410and440may comprise a monolithic silicon, germanium, gallium arsenide, indium phosphide, zinc oxide, zinc sulfide, cadmium selenide, or other Group IV, Group III-V, or Group II-VI semiconductor substrate, with one or more epitaxial (e.g., monocrystalline) or polycrystalline Group IV, Group III-V, or Group II-VI semiconductor layers or thin films thereon, which may be patterned and/or doped in a manner providing one or more waveguides thereon or therein, and optionally one or more insulator films or layers thereon or therein. For example, the first and second photonics chips or ICs410and440may comprise a plurality of waveguides (e.g., formed by ion implantation and annealing) in a conventional silicon-on-insulator substrate).

The optical emitter or transmitter420may comprise a grating coupler, a mirror or other reflector, or a laser diode (see, e.g.,FIGS. 6A-Dand the discussion thereof below). The grating coupler may be conventional, and may comprise a plurality or series of periodic notches, troughs, depressions or projections in a waveguide (see, e.g.,FIG. 6B) such that light is diffracted by the notches, troughs, depressions or projections and constructively interferes in a direction toward a target (e.g., the reflecting mirror430). Grating couplers are advantageous when polarization selectivity (e.g., the optical signal being transferred has a predetermined polarization type) is desired.

Alternatively, the reflector may comprise a mirror external to a waveguide (see, e.g.,FIG. 6C) or a facet reflector in the waveguide (see, e.g.,FIG. 6D). The mirror and facet reflector are configured to reflect the light beam towards the reflecting mirror430.

The laser diode (see, e.g.,FIG. 6A) may be a double heterostructure laser, a separate confinement heterostructure laser, a quantum well laser, a quantum cascade laser, an interband cascade laser, a distributed Bragg reflector laser, a distributed feedback laser, a vertical cavity laser, a vertical-cavity surface-emitting laser [VCSEL], a vertical external-cavity surface-emitting laser [VECSEL], an external-cavity diode laser, or other device that converts an electrical current or signal into light.

When the optical emitter or transmitter420comprises a grating coupler, the grating coupler may be round, oval, square, rectangular, hexagonal, octagonal, etc. The grating coupler may have width and length dimensions (or, alternatively, a diameter) of from 1 to 100 μm, or any length, width, diameter or range of lengths, widths, and/or diameters therein (e.g., a diameter of from 5 to 20 μm). The light422may have an axis of from 0° to 45° from normal (i.e., from a line between and perpendicular to the first and second photonics chips or ICs410and440) in the X direction, or any angle or range of angles therein (e.g., from 5° to 25°). The light422may also have a beam spread of from, e.g., 1° to 15°, or any angle or range of angles therein.

Each of the reflecting mirror430and the focusing mirror435may comprise a shallow spherical depression or indentation in an uppermost or outermost surface of the first and second photonics chips or ICs410and440, respectively. The depressions or indentations may comprise or be plated with a reflective material, such as a metal, in accordance with known techniques.

The reflecting mirror430and the focusing mirror435may have a shape and dimensions suitable for their respective functions. In some embodiments, the reflecting mirror430has dimensions (e.g., a depth, an arc and/or a radius or diameter) such that the reflected light424has a radius or diameter that neither increases nor deceases significantly (e.g., that has a constant width). Optionally, the reflecting mirror430may collimate (or preserve the prior collimation of) the reflected light424.

The reflected light424is both further reflected by and focused by the focusing mirror435. The focusing mirror435may thus have dimensions configured to provide both a reflecting function and a focusing function. In some cases, the reflecting mirror430and the focusing mirror435may have identical dimensions, but in other embodiments, the focusing mirror435may have an arc slightly greater than that of the reflecting mirror430. Alternatively, the focusing mirror435may have a depth slightly greater than and/or a diameter slightly less than that of the reflecting mirror430. The focusing mirror435generally focuses the further reflected light426onto a target, such as the optical receiver or detector450.

For example, each of the reflecting mirror430and the focusing mirror435may have a diameter of from 10 to 200 μm, or any diameter or range of diameters therein (e.g., from 30 to 100 μm), and a depth of from 0.2 to 20 μm, or any depth or range of depths therein (e.g., from 1 to 10 μm). Alternatively, the reflecting mirror430and the focusing mirror435may have an arc of from 5° to 40°, or any angle or range of angles therein.

The optical receiver or detector450may comprise a grating coupler, a mirror or other reflector, or a photodiode. In some embodiments, the optical receiver or detector450may have an identical or substantially identical structure and/or dimensions as the optical emitter or transmitter420, and the axes of the light422and the further reflected light426may be parallel. Thus, when the optical receiver or detector450comprises a grating coupler or a mirror or other reflector, the second photonics chip or IC440may comprise one or more waveguides in one or more epitaxial or polycrystalline semiconductor layers or thin films on a semiconductor substrate.

In addition, the center-to-center spacing between (i) the optical emitter or transmitter420and the focusing mirror435and (ii) the reflecting mirror430and the optical receiver or detector450may be identical. In the example shown inFIG. 4, this spacing may be determined by the formula 2D*tan α, where D is the distance between the first and second photonics chips or ICs410and440, and a is the angle of the axis of the light422. Thus, in some embodiments, both the reflecting mirror430and the focusing mirror435can focus the reflected light, and they may both have the same focusing distance. The system400may further comprise a spacer (not shown) to ensure accuracy of the distance D (e.g., within a certain error limit or margin). Thus, in embodiments in which the first photonics chip or IC410has a reflector435and the optical emitter or transmitter420on the same (e.g., uppermost) surface, and the second photonics chip or IC440has the reflector430and the optical receiver450on the same (e.g., uppermost) surface, the distance between the surfaces of the two chips or ICs410and440may equal the focusing distance of the reflectors430and435. The light signal received at the light receiver or detector450may be subsequently processed by one or more conventional techniques.

FIG. 5Ais a graph500showing the simulated coupling tolerance510(including the 1 dB alignment tolerance520) in the X direction (FIG. 4) in μm for the exemplary chip-to-chip photonics system400ofFIG. 4. The simulations producing the results shown inFIGS. 5A-Binclude the same optical emitter, chip-to-chip spacing and light beam parameters as for the simulation producing the results shown inFIG. 3B. At a coupling loss of 1 dB (i.e., 1 dB less than the maximum signal strength of the light transmitted from the first photonics chip or IC410to the second photonics chip or IC440, designated by the dashed horizontal line525), the tolerance520is about 15.3 μm. This means that, in the model system400ofFIG. 4, the photonics chips or ICs410and440can be misaligned in the X direction by up to about 15 μm with less than a 1 dB loss in signal strength. This result is more than 6 times better than the conventional system200inFIG. 2.

FIG. 5Bis a graph550showing the simulated coupling tolerance560(including the 1 dB alignment tolerance570) in the Z direction (FIG. 4) in μm for the exemplary chip-to-chip photonics system400ofFIG. 4. At a coupling loss of 1 dB (designated by the dashed horizontal line575), the tolerance570is about 15.0 μm. This means that, in the model system400ofFIG. 4, the photonics chips or ICs410and440can be misaligned by up to 15 μm in the Z direction with no more than a 1 dB loss in signal strength. This result is also more than 6 times better than the conventional system200inFIG. 2.

Exemplary Optical Transmitter-Receiver Systems

FIGS. 6A-Dshow exemplary optical transmitter-receiver systems600,602,604and608. Each of the exemplary optical transmitter-receiver systems600,602,604and608includes first and second photonics chips or ICs610and620, but with different optical transmitting and receiving mechanisms.

FIG. 6Ashows an exemplary optical transmitter-receiver system600, including an optical emitter612on the first photonics chip or IC610and an optical receiver622on the second photonics chip or IC620. The optical emitter612may comprise, for example, a laser diode or a light-emitting diode (LED). The optical receiver622may comprise, for example, a photodiode, a photosensor, or a photoresist. Each of the first and second photonics chips or ICs610and620may have an insulator and/or light-blocking layer614or624thereon, configured to expose the light-emitting or light-receiving portions of the optical emitter612or optical receiver622, and protect the parts or regions of the first and second photonics chips or ICs610and620covered by the insulator and/or light-blocking layer614or624.

The optical emitter612receives an electrical signal (not shown) and emits a light beam or signal616in response thereto. To encode data on the light beam or signal626, the electrical signal may vary (e.g., correspond to digital or binary data states). Alternatively, the first photonics chip or IC610may further comprise an optical modulator (not shown) that modulates the light beam before emission (as an optical signal) from the first photonics chip or IC610.

The light beam or signal616is then reflected by a mirror (e.g., mirror430inFIG. 4) on the second photonics chip or IC620towards a target on the first photonics chip or IC610. Typically, the target is a reflecting and focusing mirror, but in some embodiments, the light receiving mechanism on the second photonics chip or IC620may be relatively distant from the light transmitting mechanism, and multiple reflections between the first and second photonics chips or ICs610and620may be implemented. Therefore, depending on the number of reflections between the first and second photonics chips or ICs610and620, the target may be a second reflecting mirror. The second reflecting mirror on the first photonics chip or IC610may be identical or substantially identical to the reflecting mirror on the second photonics chip or IC620.

The reflected light beam or signal (e.g., light beam or signal424inFIG. 4) is further reflected and focused by a mirror (e.g., reflecting and focusing mirror435inFIG. 4). The mirror further reflects the reflected light beam or signal towards the optical receiver622on the second photonics chip or IC620, and may focus the further reflected light beam or signal on the optical receiver622. The optical receiver622may then convert the further reflected light beam or signal that it receives to an electrical signal or use the received light to change a property or characteristic of one or more materials in the optical receiver622.

FIG. 6Bshows a second exemplary optical transmitter-receiver system602, including a first waveguide630in the first photonics chip or IC610, a first grating coupler650on the first photonics chip or IC610, a second waveguide640in the second photonics chip or IC620, and a second grating coupler660on the second photonics chip or IC620. The insulator and/or light-blocking layers614and624, which may be the same or substantially the same as in the system600inFIG. 6A, also provide a waveguide cladding function.

The first waveguide630carries a light beam or signal632to the first grating coupler650, which reflects and/or refracts some or all of the light beam or signal632to a mirror (e.g., mirror430inFIG. 4) on the second photonics chip or IC620, as described herein. The mirror on the second photonics chip or IC620towards a target on the first photonics chip or IC610, as described above. When the target is a second mirror, the second mirror may further reflect (and optionally focus) the reflected light onto the second grating coupler660on the second photonics chip or IC620. The second grating coupler660then reflects and/or refracts the further reflected light beam or signal644into the second waveguide640in the second photonics chip or IC620, where the coupled light beam or signal642is then further processed (e.g., by optical processing hardware or circuitry, such as an optical modulator, an optical coupler, a photodiode, etc.).

FIG. 6Cshows a third exemplary optical transmitter-receiver system604, including a first waveguide635in or on the first photonics chip or IC610, a first planar mirror670in or on the first photonics chip or IC610, a second waveguide645in the second photonics chip or IC620, and a second planar mirror680on the second photonics chip or IC620. The optical transmitter-receiver system604further includes second insulator and/or light-blocking layers618and628, which may provide some mechanical support for the first and second planar mirrors670and680(e.g., during manufacturing), in addition to light-blocking and/or electrical insulation functions for parts or portions of the first and second photonics chips or ICs610and620that do not include a waveguide. The insulator and/or light-blocking layers614and624, which cover the first and second waveguides635and645, respectively, are the same or substantially the same as in the systems600and602inFIGS. 6A-B.

In the optical transmitter-receiver system604, light632transmitted through the first waveguide635is reflected by the first planar mirror670towards a target on the second photonics chip or IC620. The first waveguide635generally has a facet at 0° relative to the plane that is normal or perpendicular to the optical axis of the light632. The first planar mirror670generally comprises a quadrilateral mechanical support block and a total reflection mirror on the angled face of the quadrilateral support block. The first planar mirror670may reflect the light632at an angle of from 15° to 165° relative to the optical axis of the light632, or any angle or range of angles therein (e.g., from 60° to 85°).

The target on the second photonics chip or IC620may be the second planar mirror680, but other targets may be used instead (e.g., a photodiode or grating coupler, as disclosed herein). The second planar mirror680may be identical or substantially identical to the first planar mirror670, but the invention is not limited thereto. Generally, however, when the light634reflected by the first planar mirror670is transmitted directly to the second planar mirror680(i.e., the reflected light634is also the transmitted light644), the angle of the angled face of the second planar mirror680is equal to the angle of the angled face of the first planar mirror670. However, additional mirrors or other reflective surfaces may further reflect or direct the reflected light634before the transmitted light644is received and/or reflected by the second planar mirror680, in which case the angle of the angled face of the second planar mirror680may be different from the angle of the angled face of the first planar mirror670. The transmitted light644is reflected by the second planar mirror680into the second waveguide645in the second photonics chip or IC620, where it is further processed as described herein.

FIG. 6Dshows a fourth exemplary optical transmitter-receiver system606, including a first waveguide636in or on a first photonics chip or IC615, a first planar mirror or facet638at an end of the first waveguide636, a second waveguide646in the second photonics chip or IC625, and a second planar mirror or facet648at an end of the second waveguide646. The insulator and/or light-blocking layers614and624, which cover the first and second waveguides636and646, respectively, are the same or substantially the same as in the systems600,602and604inFIGS. 6A-C.

In the optical transmitter-receiver system606, light632transmitted through the first waveguide636is reflected by the first planar mirror or facet638towards a target on the second photonics chip or IC625. The first mirror or facet638is at an angle of from 15° to 75° relative to the plane that is normal or perpendicular to the optical axis of the light632, or any angle or range of angles therein (e.g., from 30° to 60°). The first planar mirror or facet638generally comprises a total reflection mirror, and may be formed by cutting, grinding or polishing the edge of the first photonics chip or IC615to expose the first waveguide636and form the surface thereof at a predetermined angle, and optionally, depositing a reflective material (e.g., a reflective metal or metal alloy) onto the angled edge to form the mirror or facet638.

The target on the second photonics chip or IC625may be the second planar mirror or facet648, but other targets may be used instead (e.g., a photodiode or grating coupler). The second planar mirror or facet648may be identical or substantially identical to the first planar mirror or facet638, but the invention is not limited thereto. Generally, however, when the light634reflected by the first planar mirror or facet638is transmitted directly to the second planar mirror or facet648(i.e., the reflected light634is also the transmitted light644), the angle of the second planar mirror or facet648is equal to the angle of the first planar mirror or facet638. Alternatively, the angle of the second planar mirror or facet648may be complementary to the angle of the first planar mirror or facet638(e.g., the sum of the angles of the first and second mirrors/facets638and648=90°). However, additional mirrors or other reflective surfaces may further reflect or direct the reflected light634before the transmitted light644is received and/or reflected by the second planar mirror648, in which case the angle of the second planar mirror or facet648may be different from the angle of the first planar mirror or facet638. The transmitted light644is reflected by the second planar mirror or facet648into the second waveguide646in the second photonics chip or IC625, where it is further processed as described herein.

An alternative of the optical transmitter-receiver system606may include one in which the first and second waveguides636and646include an angled mirror or facet638or648at a respective end thereof, but in which the substrate is not angled, and extends beyond the angled mirror or facet638or648. In this alternative system, a substrate, an insulator and/or light-blocking layer similar or identical to the second insulator and/or light-blocking layers618and628, and a quadrilateral dummy structure similar or identical to the first and second planar mirrors670and680shown inFIG. 6Care present. The first and second waveguides636and646(FIG. 6D) are formed on the quadrilateral dummy structures such that the angled ends638and648of the first and second waveguides636and646contact the angled surfaces of the dummy structures. The dummy structures can then be selectively etched to form reflective mirrors or facets similar or identical to the angled mirrors or facets638and648, but with some structures providing additional mechanical support and/or protection to the angled mirror or facet at the end of each waveguide.

Exemplary Optical Waveguides

FIGS. 7A-Bshow cross-sections of exemplary optical waveguides suitable for use in the exemplary optical transmitter-receiver systems600,602,604and606. Although the invention is not limited to the exemplary optical waveguides shown inFIGS. 7A-B, there are typically two types of optical waveguides having a structure as shown inFIGS. 7A-B. The different types of optical waveguides have different mechanisms for creating an effective reflective index difference between the core material and the cladding material to enable optical confinement in the core material.

In one type of optical waveguide, the core includes a high refractive index material, and the cladding includes a low refractive index material. Most or all of the core material (e.g., 90% or more of its length) is not doped, except in active devices such as a modulator or an attenuator (which may constitute 10% or less of the length of the core material), where doping-induced carriers are used to manipulate the light in the waveguide. For example,FIG. 7Ashows an exemplary optical waveguide700, including a silicon wafer substrate710, an n-doped silicon layer720, a p-doped silicon layer725, and an overlying dielectric layer740. The exemplary optical waveguide700inFIG. 7Aincludes a fin region730with a vertical p-n junction735. The portions of the n-doped silicon layer720and the p-doped silicon layer725outside the fin region730function as electrodes for the waveguide, in which the vertical p-n junction735is the medium through which the light (e.g., the optical signals) are carried. Each of the electrodes may further comprise a metal contact through the dielectric layer740to an overlying metal wire or layer (not shown). The substrate710and the dielectric layer740function at least as cladding and optionally as mechanical support and/or passivation for the waveguide. Thus, the substrate710and the dielectric layer740may comprise materials having a refractive index lower than the materials in the fin region730of the waveguide700. Consequently, the waveguide700shown inFIG. 7Amay function as a waveguide or as an active device. In variations of the waveguide700, the waveguide core730may comprise or consist essentially of undoped silicon or silicon nitride (Si3N4), and the cladding material (i.e., dielectric layer740and the uppermost layer of the substrate710) may comprise or consist essentially of SiO2, as in a conventional silicon photonics platform.

In another type of optical waveguide, the core and cladding include the same material, but the core is doped, resulting in a slightly higher refractive index. For example,FIG. 7Bshows an exemplary alternative optical waveguide700′, including a glass (e.g., undoped silicon dioxide) substrate710, a light-carrying region760, and an overlying dielectric layer745. The light-carrying region760comprises a doped glass (e.g., silicon oxide) layer, and the dielectric layer745includes an undoped glass (e.g., silicon dioxide), as in a conventional glass-based photonics integrated circuit. Alternatively, the light-carrying region760may comprise or consist essentially of silicon nitride, in which case the overlying dielectric layer745may comprise or consist essentially of doped or undoped silicon dioxide, and the substrate710may have an uppermost layer comprising or consisting essentially of doped or undoped silicon dioxide.

Typically, the cross-sectional area of the fin region730and the light-carrying region760has a height of from 100 nm to 1000 nm or any value or range of values therein (e.g., from 100 to 300 nm) and a width of from 200 nm to 10,000 nm or any value or range of values therein (e.g., from 1000 to 5000 nm).

Exemplary Mirrors

FIGS. 8A-Cshow exemplary reflecting and/or focusing mirrors800,802and804, suitable for use in the present chip-to-chip light transfer system. For example,FIG. 8Ashows a reflecting and/or focusing mirror800, comprising a concave depression, indentation or “dimple”820in a substrate810. The substrate810is generally as described herein. The depression, indentation or dimple820may have a shape complementary to a spherical cap, spherical dome, or spherical segment, in which the maximum depth d of the depression, indentation or dimple820is much less than the radius r of the sphere corresponding to the spherical cap, spherical dome, or spherical segment (e.g., d≤r/n, where n is a number of four [4] or greater, such as 5, 6, 8, 10 or more). The curved mirror800is advantageous for optical signals having multiple wavelengths of light (e.g., so-called multi-channel optical signals).

The depression, indentation or dimple820may be formed in accordance with known techniques and/or plated with a reflective material, such as a metal, in accordance with known techniques (see, e.g., Hou, M. T.-K., et al., “Design and fabrication of surface-micromachined spherical mirrors,” IEEE/LEOS International Conference on Optical MEMs, Lugano, Switzerland, Aug. 20-23, 2002, pp. 195-196, the relevant portions of which are incorporated herein by reference). Alternatively, a trench having a square, rectangular, hexagonal, octagonal or circular shape (in a plan view) with a width, length and/or diameter of 1-10 μm can be formed in accordance with known techniques (e.g., photolithographic patterning and etching of the substrate810), filled with a relatively soft material (e.g., a metal such as aluminum, chromium, titanium, etc.), and polished using conventional mechanical or chemical-mechanical polishing, resulting in formation of a “dish” or substantially spherical depression in the material in the trench.

FIG. 8Bshows a reflecting and/or focusing mirror802, comprising a convex lens830having a dome-shaped or otherwise curved surface832on a substrate812. The lens830is transparent or substantially transparent to the light being transferred from one photonics chip to another. The surface of the substrate812reflects the light, and thus the substrate812may have a reflective material, such as a metal, on its uppermost and/or outermost surface. In such embodiments, the combination of the substrate812and the lens830function as a focusing mirror. The lens830generally has a refractive index greater than air, in which case the light is refracted at the surface832and is optionally focused by the lens, before and/or after being reflected by the substrate812. Thus, the lens830may be advantageous for monochromatic (i.e., single-wavelength) light, as the lens830may introduce undesired dispersion in light having multiple wavelengths (e.g., multi-channel optical signals).

The substrate812is generally as described herein, but has a planar surface on which the lens830is mounted or otherwise formed. The lens830may have a shape of or similar to a spherical cap, spherical dome, or spherical segment, in which the edges may be removed to form one or more sidewalls834. In such embodiments, the lens830may have a maximum thickness t that is much smaller than the radius r of the sphere corresponding to the spherical cap, spherical dome, or spherical segment (e.g., t≤r/n, where n is a number of four [4] or greater, such as 5, 6, 8, 10 or more). The lens830may be formed in accordance with known techniques. For example, a conventional photoresist that is transparent to the wavelength(s) of light being transferred may be conventionally deposited and patterned, then heated to its reflow temperature to soften and/or round the corners of the patterned photoresist, resulting in a lens having a curved upper surface. Alternatively, the curved upper surface of the patterned photoresist can be transferred to an underlying transparent dielectric material (e.g., silicon dioxide) by non-selective, anisotropic dry etching.

FIG. 8Cshows an alternative reflecting and/or focusing mirror804, comprising a convex lens830′ having a dome-shaped or otherwise curved surface832′ on a substrate814and in and/or over a trench825in the substrate814. The substrate814is as described with respect toFIG. 8B, except that the trench825is conventionally formed in the substrate814. For example, the trench825may be formed by photolithographic patterning and dry etching such that the corners of the substrate814at the top of the trench825are rounded. The lens830′ may have a shape of or similar to a spherical cap, spherical dome, or spherical segment, which may be truncated as in the reflecting and/or focusing mirror802ofFIG. 8B. In such an embodiment, the light may be refracted at one or both of the planar surface836and the curved surface832′ of the lens830′, before and/or after being reflected by the substrate814.

The lens830′ may be formed separately, and placed on the substrate814in or over the trench825by known techniques (e.g., sheet-to-wafer placement and transfer, pick-and-place processing [for sufficiently large lenses830′] etc.). An adhesive may be deposited on the substrate814at the edges or periphery of the trench825and or the lens830′ prior to placement of the lens830′ on the substrate814.

The lens830′ may have a width and length (or diameter) slightly greater than the trench825. The trench825may have a depth greater than the distance by which the curved surface832′ extends the thickness of the lens830′ beyond its thickness at the sidewalls834. Alternatively, the lens830′ may be supported by vertical support structures (not shown) to which the lens830′ may be attached or adhered (e.g., as shown inFIG. 8Cor, alternatively, at its sidewalls834), as described herein and/or in accordance with known techniques.

An Exemplary Method of Transferring an Optical Signal from a First Photonics Chip/IC to a Second Photonics Chip/IC

FIG. 9is a flowchart900showing an exemplary method of transferring an optical signal from one photonics chip or IC to another. For example, at910, an optical signal is emitted or transmitted an optical signal from a first photonics chip or IC, as described herein. For example, the optical signal may be emitted from a laser diode or other optical signal generator on the first photonics chip or IC. Alternatively, the optical signal may be transmitted from a grating coupler or reflective surface on the first photonics chip or IC. The optical signal is generally emitted or transmitted to a target on a second photonics chip or IC, such as a reflective (or reflecting) mirror, as described herein.

At920, the optical signal is reflected by a reflecting mirror on the second photonics chip or IC, as described herein. Optionally, the reflecting mirror may also focus the optical signal. The optical signal is generally reflected to a target on the first photonics chip or IC, such as a focusing mirror, as described herein.

At930, the optical signal is reflected and focused by a focusing mirror on the first photonics chip or IC. Thus, the focusing mirror may also be a focusing and reflecting mirror. The focusing mirror reflects the optical signal towards and focuses the optical signal on a second target on or in the second photonics chip or IC, such as a grating coupler, a reflective surface, or a photodiode, as described herein.

Alternatively, the second target on the second photonics chip or IC may be or comprise a second reflecting mirror. Optionally, the second reflecting mirror may be or comprise a focusing and reflecting mirror. In such an alternative, the second reflecting mirror reflects the optical signal to a second mirror on the first photonics chip or IC. The second mirror on the first photonics chip or IC as may be or comprise a second focusing mirror or a focusing and reflecting mirror, as described herein. The number of mirror pairs reflecting the optical signal between the first and second photonics chips or ICs may depend on the positions of and spacing between the first and second photonics chips or ICs, the angle(s) of the second photonics chip or IC relative to the first photonics chip or IC, etc.

In a further alternative, when additional mirror pairs (i.e., beyond the reflecting mirror on the second photonics chip or IC and the focusing mirror on the first photonics chip or IC) are present, one or more of the mirrors may be on structures other than the first or second photonics chip or IC. For example, when the first and second photonics chips or ICs are housed in an optical or optoelectronic transceiver, one or more of the mirrors may be on a substrate or mounting surface in the optical or optoelectronic transceiver. In some embodiments, the surface on which the one or more mirrors is/are located is parallel to the surface of the corresponding first or second photonics chip or IC.

At940, the optical signal is received in or on the second photonics chip or IC, and processed by other components in or on the second photonics chip or IC. For example, the optical signal may be received by or at a grating coupler, a reflective surface, or a photodiode. When the optical signal may be received by the grating coupler or is reflected by the reflective surface, the optical signal may be transferred to a waveguide in the second photonics chip or IC. The optical signal may travel in the waveguide to another component in the second photonics chip or IC for further processing, such as a photodiode, an optical coupler, an optical phase shifter, a modulator, combinations thereof, etc.

An Exemplary Method of Manufacturing a Chip-to-Chip Optical Signal Transfer System

The present optical signal transfer system is advantageously implemented as first and second photonic integrated circuits (PICs). For example, some or all of the components of the present optical signal transfer system may be formed in first and second silicon PICs (Si PICs). Accordingly, the present invention also relates to a method of manufacturing an optical signal transfer system, comprising forming an optical transmitter or emitter and a first mirror on or in a first photonic integrated circuit, forming an optical receiver and a second mirror on or in a second photonic integrated circuit, and mounting or securing the first and second photonic integrated circuits face-to-face, such that an optical signal from the optical transmitter or emitter is reflected by the second mirror, the reflected optical signal (directly or indirectly from the second mirror) is focused and further reflected by the first mirror, and the focused and further reflected optical signal is received by the optical receiver.

Preferably, as many of the components of the optical signal transfer system are formed on the first and second PIC substrates as possible. Thus, in various embodiments, the method of manufacturing may further include forming a respective waveguide in each of the first and second PICs, forming a cladding layer and/or passivation on or over the waveguide(s), forming a mirror at adjacent to an end of the waveguide(s), forming a grating coupler on or over the waveguide(s), forming a lens on or above one or more of the mirrors, forming a laser diode in the first PIC, and/or forming a photodiode in the second PIC. If the lens is formed above the mirror(s), the method further comprises forming, mounting or attaching a physical support structure on the PIC adjacent to the mirror, and attaching the lens to or integrating the lens in the physical support structure.

In further embodiments, a complex or multi-channel optical signal transfer system may include multiple chip-to-chip optical signal transfer sub-systems. For example, the first PIC may include a plurality (e.g., 2, 4, 8 or more) of optical signal emitters or transmitters and an equal number of focusing mirrors, and the second PIC may include numbers of reflecting mirrors and optical signal receivers equal to the number of optical signal emitters or transmitters. Alternatively, the optical signal emitter or transmitter-focusing mirror pairs may be on separate first PICs, and the optical signal receiver-reflecting mirror pairs may be on separate second PICs. In general, each of the optical signal emitters or transmitters in the multi-channel optical signal transfer system emits or transmits a different wavelength of light. The different wavelengths of light may differ by at least 4 nm (e.g., 8 nm, 20 nm, etc.).