Manufacturing of LiNbO3 channel optical guides

Abstract: The invention regards a manufacturing process for high performance Single mode channel optical guides, obtained on surface "X' of the LiNbO3, and based upon five successive steps: photo-etched optical path definition, deposition of the dielectric layer, lift-off definition of the channels, proton exchange and thermal cycling. It belongs to the field of integrated optical technologies and it can be applied profitably to the manufacturing of multi-function devices to be interfaced with optical fibres to obtain sensors,telecommunications devices and devices to process wide-band microwave signals. This process provides self-aligned optical guides and the dielectric layers required to isolate the guides from the metal electrodes exploiting the in-built characteristics of the manufacturing process based upon proton exchange in Benzoic acid diluted with Lithium Benzoate, and at the same time it eliminates the time instability of the electro-optical structure due to the presence of the insulating layer above the optical guide.

Description: This invention regards a new manufacturing process of Lithium Niobate channel optical guides, obtained in particular on its 'X' cut surface, where a thin dielectric film, within which the channel is defined by photo etching , is used as a template while manufacturing the optical guide and as an insulating film between this guide and the metal electrodes, resulting in a self-aligning process. A similar method, corresponding to the preamble of claim 1, is known from EP-A-340 983. This process pertains to the field of planar integrated optical componenent technologies and it can be advantageously applied to the manufacturing of components used for optical fibre sensors (Reference #1:W.C.Gross et al, Applied Optics, Vol 19,#6, page 852-858, 1980) and for wide band microwave signal processing (Reference #3:T.Sueta and M.Izutsu, IEEE Trans.on Microwave Theory and Techniques, Vol.38,#5, page 477-482, May 1990). It is a known fact that previously the manufacturing of channel optical guides when in particular meant for phase modulators based upon Lithium Niobate electro-optical effects, suffered of the following drawbacks: complexity of the manufacturing process constance of the electro-optical characteristics of structure due to the presence of the insulating layer above the optical guide and the material within which the optical guide is manufactured (Reference #4:R.A.Becker, Appl.Phys.Lett. vol.43, pag.131-133, 1983) elimination of the time-dependent instabilities of the optical and electro-optical characteristics of the device (Reference #5:J.L.Jackel and C.E.Rice, "Proceedings of Giuded Wave Optoelectronic Material", SPIE vol 460, pag.43-48, 1984). The manufacturing of LiNbO3 channel optical guides more often adopted at present consists of the diffusion of Titanium into the Lithium Niobate crystal (Ref #6: W.K.Burns et al, J.Appl.Phis.,vol.50,#10, pag.6175-6182,October 1979) and of the following deposition of a dielectric film followed by the deposition and definition of the metal electrodes. This process is costly in terms of deposition and definition of the Titanium film (complex high accuracy equipment required to determine the thickness of the film) and of the following thermal diffusion of Titanium into the crystal (temperature control at about 1000 deg C). The proton exchange in acid solution between Li (Li + ) of the crystal and the solution protons (H+) has shown the possibility to cut the complexity of the manufacuting process by a very large amount (Ref.#7:K.K.Wong,Spie Vol.993 "Integrated Optical Circuit Eng.VI". pag.13-25,1988),but affected negatively by a reduced electro-optical efficiency of the devices. Eventually, the presence of the dielectric film above the optical guide, independently from its manufacturing process, gives way to an instability of the modulator electro-optical characteristics. To eliminate this effect, the dielectric film must be removed above the optical guide (Ref #8: Yamada et al, Japan J.Appl.Phys. vol.20,#4, pag.733-737, April 1981). The process dealt with by this patent application offers the following advantages: simplification of the manufacturing process no modification of the electro-optical efficiency elimination of the electro-optical instability characteristics. This is made possible by the adoption of a template in the proton exchange process, which consists of a dielectric film which is deposited onto the surface and which carries the optical guide channel and also by the thermal tratment which follows the exchance phase. The use of a dielectric film covers with one action both the function of proton exchange template and the provision of an insulating layer between the optical guide and the metal electrodes which are later implemented. At the same time, the resulting isolation layer is not present above the optical guide, so as to eliminate the causes of instability of the electro-optical characteristics of the modulator. The invention will now be descrtibed for illustrative and non limiting purposes with reference to the drawings attached. Figure 1 shows a schematic outline of the manufacturing process phases where we can see: 1 result of the photo etched definition of a polymer which corresponds to the channel to be formed in the template for the proton exchange; 2 LiNbO3 substrate, "x" cut; 3 photo-etched PMMA definition; 4 result of the deposition of the dielectric thin film; 5 SiO2 layer; 6 result of the openeing of the channel in the dielectric film by lifting the polymer; 7 result of the proton exchange; 8 result of the thermal treatment; 9 schematic diagram of the refractive index profile. Figure 2 is a diagram of the structure of the modulator where we can see: 10 optical guide; 11 insulating layer; 12 metal electrodes; 13 electric field; 14 optical radiation input; 15 phase modulated optical radiation output. Once more for non limiting descriptive purposes we shall now illustrate the sequence of phases of the manufacturing process of the optical guide and of the insulating layer along the lines of Figure 1: a)photo-etch definition of a PMMA structure (Poly Methil Meta Acrylate) 500 nm thick corrisponding to the channel left free by the dielectric layer and through which the exchange will be later effected (figure 1.1) b) deposition by magnetron sputtering in oxidising ambient (RF power density at the cathode of 3 W/cm2, partial pressure of Argon =2x10-3 Torr, partial pressure Oxigene 1x10-3 Torr) of a Silicon dioxide (SiO2) film 200nm thick (figure 1.2) c) removal of the SiO2 layer from the channel by polymer lift-up by immersion in a solvent (Acetone) (figure 1.3) d)Proton exchange in 1% Benzoic Acid with Lithium Benzoate (temperature of the solution +235 deg C, duration of the exchange 35 minutes) throught he template formed by the Silicon dioxide layer (Figure 1.4) e) Thermal treatment for interdiffusion of the protons present in the layer exchanged and the Lithium atoms present in the crystal regions close to the same layer (temperatore 350 deg C in Oxigene, duration 50 minutes) (figure 1.5). At the end of the process, outlined above, an increase of the refractive index in the interdiffused Li-H area is obtained, qhich makes possible the restriction of the laser optical radiation to 830 nm, resulting in a single mode optical guide for TE polarisation. At the same time, the optical guide is self aligned with a channel defined in a dielectric layer which is used as an isolation layer between it and the elctrodes of a generic modulator which is shown as an elementary structure in Figure 2. The elementary modulator presently preferred by the inventors has the following characteristics: in-guide optical propagation loss +1 dB/cm coupling loss with a polarisation conservation fibre =0.4 dB voltage required to introduce a phase delay of the optical radiation equal to 0.5 wavelengths =1.4 Volt The main advantages of the process described are the following: The optical guide and the isolating film between the guide and the metal electrodes are obtained in a self-aligning method by using a layer of Silicon Dioxide as a template for the proton exchange process; the presence of the insulating dielectric layer above the guide is eliminated, solving the problem of time instability of the electro-optical structure, known as DC drift, caused by the presence of the insulating layer even above the guide; the electro-optical efficiency characteristics of the LiNbO3 crystal are not affected by the process.

Claims: Method of making an electro-optical device having at least one single mode optical waveguide comprising the steps of: a) providing an optical substrate of LiNbO 3 ; b) masking the surface of said substrate with a Si0 2 film so as to define an uncovered waveguide structure; c) effecting proton exchange along the uncovered structure of the surface in order to modify the optical properties of said substrate along said uncovered structure; d) thermally treating said substrate in an oxygen atmosphere to effect interdiffusion of protons in an exchange layer along said uncovered structure, thereby forming in said substrate a single mode optical waveguide; characterised in that said optical substrate is an X-cut crystal; the mask for defining the waveguide structure is performed according to the following steps: aa) photo-etch definition of a PMMA (Poly Methyl Meta Acrylate) structure, having a thickness of 500 nm that corresponds to the uncovered structure desired, bb) deposition of the Si0 2 film of 200 nm thickness across the surface of said substrate including said PMMA structure, cc) removal of the Si0 2 film from the waveguide structure by lifting the PMMA structure by immersion in a solvent; said deposition of the Si0 2 film is effected by magnetron sputtering in an oxidizing environment of argon and oxygen, said proton exchange is effected in a 1% diluted Benzoic Acid with Lithium Benzoate at a temperature of about 235°C and for a duration of about 35 minutes, said thermal treatment is effected at a temperature of about 350°C for about 50 minutes, applying metal electrodes to said Si0 2 film along opposite longitudinal sides of said waveguide structure.

Inventors: VANNUCCI ANTONELLO, VARASI MAURO, VANNUCCI, ANTONELLO, VARASI, MAURO
Applicants: ALENIA MARCONI SYSTEMS SPA, ALENIA MARCONI SYSTEMS S.P.A.
Application year: 1992
Main classification: G02B6
IPC codes: G02B6