US20230367061A1 - Carrier based laser assembly and method of assembly thereof with photonic integrated circuit - Google Patents
Carrier based laser assembly and method of assembly thereof with photonic integrated circuit Download PDFInfo
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- US20230367061A1 US20230367061A1 US18/222,546 US202318222546A US2023367061A1 US 20230367061 A1 US20230367061 A1 US 20230367061A1 US 202318222546 A US202318222546 A US 202318222546A US 2023367061 A1 US2023367061 A1 US 2023367061A1
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Definitions
- photonic and/or silicon photonics based optical engines require multiple laser sources to support multiple lanes of data.
- the need for a greater number of lasers is, for example, because higher optical reflection tolerance often dictates lower output power that, in turn, supports fewer channels.
- This high number of lasers necessitates very high single-device laser yield in the integrated optical engine because the cumulative yield is compounded by the number of devices used.
- the lowest-loss and most cost-effective assembly methods require that the laser light source is directly attached to silicon photonics.
- FIG. 1 depicts a top view of an example device that includes a carrier and a laser, in accordance with some examples.
- FIG. 2 depicts a side view of the example device of FIG. 1 , in accordance with some examples.
- FIG. 3 depicts an end view of the example device of FIG. 1 , in accordance with some examples.
- FIG. 4 depicts a perspective view of the example device of FIG. 1 , in accordance with some examples.
- FIG. 5 depicts an end view of the laser being attached to the carrier of example device of FIG. 1 , in accordance with some examples.
- FIG. 6 depicts a perspective view of the example device of FIG. 1 being tested and/or burned-in, prior to attachment to a photonic integrated circuit, in accordance with some examples.
- FIG. 7 depicts a perspective view of the example device of FIG. 1 being positioned relative to a cavity of an example PIC, in accordance with some examples.
- FIG. 8 depicts an end view of the example device of FIG. 1 being more precisely aligned at the PIC, in accordance with some examples.
- FIG. 9 depicts a side view of the example device of FIG. 1 attached to the PIC with respective planes, optical axes, waveguides and facets aligned, in accordance with some examples.
- FIG. 10 depicts a top view of the example device of FIG. 1 attached to the PIC with respective planes, optical axes, waveguides and facets aligned, in accordance with some examples.
- FIG. 11 depicts a top view of the example device of FIG. 1 attached to the PIC in an alternative manner that uses a polymer waveguides, in accordance with some examples.
- FIG. 12 depicts a flowchart of a method for attaching the example device of FIG. 1 to a PIC, in accordance with some examples.
- FIG. 13 depicts an alternative device that includes a carrier and a laser attached to an alternative PIC with a polymer waveguide used to optically connect facets thereof, in accordance with some examples
- such lasers may require soldering (e.g. Au—Sn soldering), as well as a post-attach burn-in for the lasers to ensure reliability of the full multi-laser assembly.
- post-attach burn-in may result in failure of the laser which can result in failure of the entire laser assembly.
- burning-in laser devices after attached to a photonic integrated circuit (PIC) is problematic due to the possibility of the laser devices failing after attachment which may lead to failure of the entire PIC, along with any previously attached lasers, and packaged assembly and hence a lowered yield in producing PIC-laser assemblies.
- maximizing yield of optical engines that includes one or more lasers and a PIC is paramount for reducing cost of production, and with multiple soldered and burned-in lasers that may be required per optical engine-die, the individual assembled laser die yield becomes critical.
- One approach is to provide a flipped active region (“p-down”) soldered to a PIC die with a mode-matched facet-to-facet coupling arrangement.
- a problem with monolithic PIC die systems with flipped LD configurations is that the soldering process takes place at the die or wafer level.
- the flipped laser for facet-coupling requires the solder joint to be within microns of the active region. The additional stresses and stress non-uniformity of this solder joint will impact the optical performance of the lasing device. The resulting overall yield of a device that uses multiple lasers may be catastrophically low.
- Facet-to-facet coupling can require sub-micron level accurate placement of a laser die in the flipped arrangement while being soldered at temperatures greater than 300° C. This process can require very expensive assembly equipment, and long development times.
- a process that allows a laser assembly to be burned-in and screened by testing after soldering (e.g. attaching a lasing device to a carrier via soldering) but before the assembly is attached to the photonics and/or silicon photonics, for example to avoid device failures after attaching the laser assembly to the photonics and/or silicon photonics.
- a laser assembly that may increase yield of laser-PIC assemblies as a laser is first attached to a carrier distinct from a PIC. Dimensions and/or configurations of the carrier are selected such that the carrier is compatible with subsequent attachment to a PIC.
- Also provided herein is a technique that may reduce the machine assisted alignment requirements in which an output portion and/or output facet of a waveguide of the laser is visible when the laser is attached to the carrier.
- dimensions and/or configurations of a combination of a laser and a carrier to which the laser is attached e.g. a laser assembly
- the output portion and/or output facet of waveguide may be aligned with a corresponding input portion and/or input facet of a waveguide of the PIC as the laser assembly is being attached to the PIC.
- the output of the laser on the carrier is generally visible during the attaching of the laser assembly onto the PIC and/or is not eclipsed by the PIC.
- Also provided herein is a technique that may reduce machine assisted alignment requirements, for example by removing one of the alignment axes, using semiconductor-based datum reference planes at both the PIC and laser assembly that are correlated to vertical optical planes.
- semiconductor-based datum reference planes at both the PIC and laser assembly that are correlated to vertical optical planes.
- a device that includes a carrier with a laser attached thereto, the laser having a region (e.g. a visible region) which is visible to an external vision system and that includes an output facet of the laser, as well as a portion of a waveguide from a lasing device of the laser to the output facet, and allows the laser to be more easily positioned at a surface of a PIC.
- the visible region may protrude from the carrier and the laser may be positioned in a cavity of the PIC as the laser is being positioned at the surface of the PIC, with the carrier interfacing with the surface of the PIC.
- a method for assembling the device with the PIC is also provided that relies on the visible portion for alignment of the output facet, and the associated waveguide, with an input facet, and respective associated waveguide, of the PIC.
- an aspect of the present specification provides device comprising: a carrier comprising: a first side, a second side opposing the first side, and an edge joining the first side and the second side; through-carrier vias (TCVs) from the first side to the second side, the TCVs including electrical connections therethrough; first electrical contacts for the electrical connections at the first side; and second electrical contacts for the electrical connections at the second side; and a laser attached to the second side of the carrier, the laser comprising: a body supporting components of the laser; a lasing device configured to produce light, the lasing device located at a respective side of the body attached to the second side of the carrier; respective electrical connections from the second electrical contacts to the lasing device; and a protruding region of the body protruding the edge of the carrier, the body otherwise having a smaller footprint than the carrier; and an output portion configured to convey light from the lasing device out of the laser, the output portion located at the protruding region of the body.
- TCVs through-carrier vias
- a device comprising: a photonic integrated circuit (PIC) including a waveguide, an input portion to the waveguide; and a cavity, the input portion located at an interior edge of the of the cavity; and a laser device comprising: a carrier comprising: opposing sides joined by an edge; through-carrier-vias (TCVs) between the opposing sides, the TCVs including electrical connections therethrough; and a laser attached to a given side of the opposing sides of the carrier, the laser comprising: a body supporting components of the laser; a lasing device configured to produce light for the PIC, the lasing device located between the given side of the carrier and the body; respective electrical connections from the lasing device to the electrical connections of the TCVs; and an output portion and respective waveguide configured to convey the light from the lasing device out of the laser, a protruding region of the body, supporting the output portion, and the respective waveguide, protruding the edge of the carrier, the body otherwise having a smaller footprint than
- PIC photonic
- Yet another aspect of the present specification provides a method comprising: burning-in a laser device, the laser device comprising: a laser attached to a carrier, a visible region of the laser, that includes an output portion and at least a portion of a waveguide configured to convey light out of the laser, the visible region being visible to an imaging system external to the laser device; positioning, using one or more of the imaging system and a robotic device, the laser device at a surface of a photonic integrated circuit (PIC) such that respective optical axes of the output portion and an input portion of a waveguide of the PIC, are about aligned; and attaching the carrier to the surface of the PIC.
- PIC photonic integrated circuit
- a device comprising: a photonic integrated circuit (PIC) including a waveguide and an input portion to the waveguide; and a laser device attached to the PIC, the laser device comprising: a carrier; a laser attached to the carrier, the laser comprising: a lasing device, a respective waveguide, an output portion, and a visible region of the laser that includes the output portion and at least a portion of the waveguide configured to convey light out of the laser via the output portion to the input portion of the PIC, the output portion and the input portion being optically coupled via an optical coupling device, the visible region being visible to an imaging system external to the laser device.
- PIC photonic integrated circuit
- facets for example of an output facet and an input facet of waveguides, such terms may be interchangeably referred, hereafter, respectively, as an output portion (e.g. of a waveguide) and an input portion (e.g. of a waveguide), though the terms output portion and input portion (e.g. of a waveguide) are understood to encompass other structures and/or configurations for emitting or receiving light at a waveguide (e.g. other than facets).
- optical coupling between waveguides may alternatively occur via at any suitable input portions and output portions of the waveguides, including, but not limited to, evanescent coupling between a polymer waveguide (and/or a three-dimensional printed polymer waveguide) and a laser waveguide and/or PIC waveguide.
- FIG. 1 , FIG. 2 , and FIG. 3 respectively depict a top view, a side-cross-sectional view (e.g. through a line A-A of FIG. 1 ), and an end view of a laser device 100 (interchangeably referred to hereafter as the device 100 and/or a laser device assembly 100 and/or an assembly 100 ).
- the device 100 comprises a carrier 101 and a laser 103 .
- the laser device 103 is attached to, and/or assembled with, the carrier 101 and laser device assembly 100 burned-in (e.g. and tested) prior to attachment to a PIC.
- the carrier 101 generally comprises any suitable material which may include, but is not limited to, silicon, silicon nitride, and the like, and/or any other suitable material (e.g. another suitable crystalline material, a suitable ceramic and the like), etched and/or cut and/or formed and/or cleaved into a suitable shape.
- the carrier 101 may comprise a silicon carrier.
- the carrier 101 generally acts as a mechanical support mechanism for the laser 103 as described in more detail below. As best seen in FIG. 1 and FIG. 2 , a portion of the laser 103 protrudes relative to the carrier 10 , and components of the laser 103 in FIG. 1 which are obscured by the carrier 101 are depicted in outline to show relative positions thereof to the remainder of the components of the device 100 .
- the carrier 101 generally comprises: a first side 111 , a second side 112 opposing the first side 111 , and an edge 113 joining the first side 111 and the second side 112 . It is understood that while one edge 113 joining the first side 111 and the second side 112 is numbered and described herein, other edges join the sides 111 , 112 ; for example, as depicted, the sides 111 , 112 have a generally rectangular shape and hence are joined by four edges including the edge 113 . However, the carrier 101 may have any suitable shape and hence any suitable number of edges.
- the carrier 101 further comprises through-carrier vias (TCVs) 115 - 1 , 115 - 2 (e.g. interchangeably referred to herein, collectively, as TCVs 115 and, generically, as a TCV 115 ) from the first side 111 to the second side 112 .
- TCVs 115 are depicted in outline indicating that they are located inside the carrier 101 .
- the TCVs may comprise through-silicon vias (TSVs).
- TCVs generally including electrical connections therethrough; for example, the TCVs may be filled with conducting material, such as aluminum, gold, and the like.
- the carrier 101 further comprises first electrical contacts 117 - 1 , 117 - 2 (e.g. electrical contacts 117 and/or an electrical contact 117 ) for the electrical connections at the first side 111 ; and second electrical contacts 127 - 1 , 127 - 2 (e.g. electrical contacts 127 and/or an electrical contact 127 ) for the electrical connections at the second side 112 .
- first electrical contacts 117 - 1 , 117 - 2 e.g. electrical contacts 117 and/or an electrical contact 117
- second electrical contacts 127 - 1 , 127 - 2 e.g. electrical contacts 127 and/or an electrical contact 127
- the electrical contacts 127 are electrically connected to respective laser electrical connections 128 - 1 , 128 - 2 (e.g. electrical connections 128 and/or an electrical connection 128 to the lasing device 123 ) via respective solder connections 119 - 1 , 119 - 2 (e.g. solder connections 119 and/or a solder connection 119 ), for example during assembly of the laser 103 to the carrier 101 .
- respective solder connections 119 - 1 , 119 - 2 e.g. solder connections 119 and/or a solder connection 119
- the carrier 101 further comprises a recess 120 at the second side 112
- the solder connections 119 may be located in the recess 120 at the second side 112 and similarly a portion of the electrical contacts 127 that connect to the solder connections 119 may also be located in the recess 120 at the second side 112 .
- the electrical connections 128 and the electrical contacts 127 may be electrically connected in any suitable manner (e.g. with electrical connections different from solder connections, for example bonded wire, conductive adhesive, contact pins, and the like).
- the TCVs 115 may not (e.g. as depicted) be aligned with the electrical connections 128 and/or solder connections 119 and hence, the electrical contacts 127 may include electrical traces and the like between an end of the electrical connections in the TCVs 115 at the second side 112 and electrical connections 128 and/or the solder connections 119 .
- the electrical contacts 127 may include electrical traces and the like between an end of the electrical connections in the TCVs 115 at the second side 112 and electrical connections 128 and/or the solder connections 119 .
- the electrical contact 117 - 1 and the electrical connection 128 - 1 are electrically connected, and the electrical contact 117 - 2 and the electrical connection 128 - 2 are electrically connected.
- the electrical contacts 117 , and the electrical contacts 127 may be formed from a same and/or similar material as the electrical connections in the TCVs 115 , however the electrical contacts 117 are of a shape and size for connecting a power and/or voltage source thereto, and the electrical contacts 127 are of a shape and size such that corresponding electrical connections 128 of the laser 103 may be soldered to electrical contacts 127 via the solder connections 119 .
- the electrical connection 128 - 1 comprises an “N” electrical connection to the lasing device 123
- the electrical connection 128 - 2 comprises a “P” electrical connection to the lasing device 123 .
- the laser 103 is generally attached to the second side 112 of the carrier 101 , for example as described in more detail below (e.g. via soldering using the solder connections 119 , and/or other suitable attachment mechanisms and/or material).
- the laser 103 comprises: a body 121 supporting components of the laser 103 ; and a lasing device 123 configured to produce light, the lasing device 123 located at a respective side 125 of the body 121 attached to the second side 112 of the carrier 101 .
- the lasing device 123 may be combined with and/or at least partially include a waveguide 129 and/or at least partially be combined with the waveguide 129 , and/or the lasing device 123 and the waveguide 129 may be coincident such that the waveguide 129 guides light from the lasing device 123 to an output facet 131 .
- the lasing device 123 may include an active guided region and a passive waveguiding region (e.g. the waveguide 129 ), where a lasing gain region of the lasing device 123 makes up only a portion of a lengthwise section of the lasing device 123 (e.g.
- the waveguide 129 may comprise a front passive waveguide section of the lasing device 123 ); regardless the lasing device 123 may generally include an active lasing section that outputs light to an active guided region, which guides light to the passive region, and/or to the waveguide 129 .
- the lasing device 123 may comprise any suitable lasing device 123 and may be formed at the body 121 and/or the waveguide 129 using any suitable process.
- the body 121 may comprise InP (Indium Phosphide) that is p-doped at the side 125 (e.g. and n-doped at an opposite side), and the lasing device 123 may comprise an InP lasing device formed at the p-doped side of the InP body 121 .
- the laser 103 may be referred to as an InP P-Up laser and/or assembly, and the like.
- the laser 103 may be fabricated using techniques familiar to those of skill in the art including, but not limited to photolithography, etching, and the like (e.g. beginning with doped InP and the like).
- the laser 103 further comprises respective electrical connections 128 from electrical contacts 127 to the lasing device 123 (e.g. via the solder connections 119 ).
- the electrical contact 127 - 1 may be soldered to the electrical connection 128 - 1 via the solder connection 119 - 1
- the electrical contact 127 - 2 may be soldered to the electrical connection 128 - 2 via the solder connection 119 - 2 .
- the laser 103 may be at least partially attached to the carrier 101 via soldering of the electrical contacts 127 and the electrical connection 128 via respective solder connections 119 .
- the laser 103 may be at least partially attached to the carrier 101 via any suitable technique and/or material including, but not limited to: bonded wire, conductive adhesive, contact pins, solder and the like.
- electrical contacts 117 and/or the electrical contacts 127 are connected to electrical components of the lasing device 123 which cause the lasing device 123 to lase and emit light.
- the electrical contact 117 - 1 may be electrically connected to an “N” electrical connection 128 - 1 of the lasing device 123 via the TCV 115 - 1 , the electrical contact 127 - 1 , and the solder connection 119 - 1
- the electrical contact 117 - 2 may be electrically connected to a “P” electrical connection 128 - 2 of the lasing device 123 via the TCV 115 - 2 , the electrical contact 127 - 2 , and the solder connection 119 - 2 , and the lasing device 123 may hence be operated via the electrical contacts 117 .
- the laser 103 further comprises a waveguide 129 which conveys light from the lasing device 123 to the output facet 131 such that the light from the lasing device 123 may exit the laser 103 .
- the waveguide 129 may comprise a passive waveguide region of the lasing device 123 .
- the output facet 131 may generally be about perpendicular to the second side 112 of the carrier 101 and is configured to convey light from the lasing device 123 out of the laser 103 (e.g. via the waveguide 129 ).
- the output facet 131 is depicted as perpendicular to the second side 112 of the carrier 101 , the output facet 131 may be at any suitable angle to the second side 112 (e.g. in a range of about 0° to about 8° (e.g. off of perpendicular) and/or any other suitable angle).
- the body 121 generally comprises a protruding region 133 , supporting the output facet 131 and protruding the edge 113 of the carrier 101 .
- the protruding region 133 may alternatively be referred to using the term “visible region”, as described throughout the present specification.
- the body 121 and/or the laser 103 otherwise has a smaller footprint than the carrier 101 .
- the body 121 of the laser 103 is generally configured (e.g. of a suitable shape and size) to reside in a photonic integrated circuit (PIC) cavity, supported by the carrier 101 .
- PIC photonic integrated circuit
- the output facet 131 is located at the protruding region 133 and/or the output facet 131 is located at an end 132 of the protruding region 133 .
- the device 100 may further comprise, at the protruding region 133 of the laser 103 and/or the body 121 , optional alignment features 135 configured to facilitate one or more of machine and human vision alignment of the output facet 131 , and the corresponding waveguide 129 of the laser 103 which ends at the output facet 131 , with an input facet, and respective waveguide, of a PIC to which the device 100 is being attached.
- the alignment features 135 comprise two crosses, arranged symmetrically around the waveguide 129 , at a face of the protruding region 133 where the waveguide 129 is located.
- the alignment features 135 when present may comprise any suitable marks, and the like, located at any suitable position at the protruding region 133 .
- the alignment features 135 are depicted as symmetric, the alignment features 135 need not be symmetric; indeed, the alignment features 135 may be any suitable shape that is recognizable to an imaging system and/or a machine vision system, having suitable contrast therefor (e.g.
- the alignment features 135 may be photoetched at the protruding region 133 during fabrication of the laser 103 .
- the device 100 may further comprise, at mating surfaces (e.g. surfaces of the second side 112 and the side 125 which mate with each other) of one or more of the carrier 101 and the body 121 , one or more of pedestals (e.g. as depicted pedestals 137 ) and recesses configured to locate the output facet 131 and a waveguide optical axis at a given plane, parallel to the second side 112 .
- mating surfaces e.g. surfaces of the second side 112 and the side 125 which mate with each other
- pedestals e.g. as depicted pedestals 137
- recesses configured to locate the output facet 131 and a waveguide optical axis at a given plane, parallel to the second side 112 .
- FIG. 4 depicts a perspective view of the device 100 , showing an end of the device 100 that includes the protruding region 133 and the output facet 131 .
- the output facet 131 includes an end of the waveguide 129 , though the output facet 131 may be recessed into the body 121 of the laser 103 (e.g. light from the lasing device 123 is generally guided by the waveguide 129 formed at a surface of the body 121 , though the light from the lasing device 123 may further travel in the body 121 adjacent the waveguide 129 ); in general, the output facet 131 comprises a portion of an end of the protruding region 133 where the waveguide 129 terminates at which light is emitted from the lasing device 123 . For example, as further depicted in FIG.
- the laser 103 further comprises a waveguide optical axis 401 , which may be parallel to the waveguide 129 and/or normal (e.g. perpendicular) the output facet 131 , however the waveguide optical axis 401 may be at any suitable angle to the waveguide 129 and/or the output facet 131 .
- the angle of the waveguide optical axis 401 may at least partially depend on the angle of the output facet 131 ; in some examples, an angle the waveguide optical axis 401 may be in a range of about 0° to about 21° (and/or at any suitable angle) due to refraction at the output facet 131 .
- the waveguide optical axis 401 generally indicates a location and direction at which light is emitted from the laser 103 .
- the output facet 131 may be perpendicular to the waveguide optical axis 401 , or at another angle thereto (e.g. the aforementioned range of about 0° to about 8° and/or any other suitable angle).
- a given plane 403 is defined by the output facet 131 and the waveguide optical axis 401 ; for example, the given plane 403 includes the waveguide optical axis 401 and may be about perpendicular to the output facet 131 (e.g. when the output facet 131 is about perpendicular to the second side 112 ) and/or the given plane 403 may be about parallel to mating surfaces of the carrier 101 and/or the laser device 100 . Indeed, as depicted, the given plane 403 is further parallel to the second side 112 of the carrier 101 . In particular, dimensions and configurations of the one or more of the pedestals (e.g.
- pedestals and recesses 137 and pedestals or recesses at the mating surfaces of one or more of the carrier 101 and the body 121 are generally selected to position the given plane 403 at a location where, when the device 100 is positioned relative to a cavity of a PIC (described below), the given plane 403 is aligned with a respective plane of the PIC (e.g. which may be about perpendicular to an input facet thereof, as described in more detail below).
- the pedestals 137 (and/or recesses) generally locate the waveguide optical axis 401 (e.g.
- the waveguide optical axis 401 is aligned with respective an waveguide optical axis (e.g. and/or input facet) of a PIC when the device 100 is positioned relative to a cavity of a PIC (and/or respective waveguide optical axes are aligned when the device 100 is positioned relative to a cavity of a PIC).
- FIG. 5 depicts an end view of the device 100 as the laser 103 is being attached to the carrier 101 .
- the carrier 101 and the laser 103 may be inverted as compared to FIG. 3 , the carrier 101 may be placed in a rig (not depicted) and/or a device for holding the carrier 101 and the like, and the laser 103 may be mated, and electrically connected, with the carrier 101 for example by soldering the electrical contacts 127 with respective electrical connections 128 to form the solder connections 119 (e.g.
- the pedestals 137 (and/or recesses) generally locate the waveguide optical axis 401 (and/or the plane 403 and/or the output facet 131 ) at a given position relative to the second side 112 of the carrier 101 , as described above.
- the device 100 may be burned-in (e.g. and tested) by operating the lasing device 123 .
- FIG. 6 depicts a perspective of the device 100 being burned-in (e.g. and/or tested).
- the electrical contacts 117 are connected to a power supply 601 and the lasing device 123 is operated such that light 603 (e.g. laser light) is emitted from the output facet 131 along the waveguide optical axis 401 and/or about along the output facet 131 (e.g. depending on an angle of the output facet 131 ).
- light 603 e.g. laser light
- the burn-in (and/or testing) process may both stabilize operation of the lasing device 123 and test the operation of the lasing device 123 .
- the light 603 may be monitored for intensity and/or wavelength, and the like, and similarly power and/or voltage used to operate the lasing device 123 at the power supply 601 may be monitored to determine whether the lasing device 123 is operating within given parameters (e.g. compatible with a PIC and/or a telecommunication system with which the device 100 is to be used (e.g. in combination with a PIC)).
- the burn-in process may continue for any suitable time, which may be determined heuristically and/or until it is determined that the lasing device 123 is operating within given parameters and/or until it is determined that the lasing device 123 is not failing. Indeed, burning-in the device 100 , prior to attachment to a PIC, may ensure that the device 100 is operating within the given parameters, which may increase yield of optical devices that include a combination of the device 100 and a corresponding PIC (e.g. relative to burning-in after attachment to a PIC).
- FIG. 7 depicts a perspective view of the device 100 being located at a PIC 700 , which comprises a cavity 701 in a surface 702 of the PIC 700 , using a robotic device 710 (e.g. a robotic arm, and the like, as depicted holding the device 100 via the carrier 101 , and the like)) and an imaging system 712 .
- the surface 702 may comprise a fixed mating surface of the PIC 700 (e.g. to which the carrier 101 is to be attached, as described in more detail below).
- the PIC 700 further includes a waveguide 729 , an input facet 731 to the waveguide 729 ; and the cavity 701 , the input facet 731 located at an interior edge 741 of the of the cavity 701 ; the input facet 731 may be perpendicular to the waveguide optical axis 751 and/or at another angle thereto (e.g. similar to the output facet 131 , in the aforementioned range of about 0° to about 8° and/or any other suitable angle).
- a waveguide optical axis 751 of the waveguide 729 and/or the input facet 731 is also depicted.
- the waveguide 729 , the input facet 731 and the waveguide optical axis 751 are substantially similar, respectively, to the waveguide 129 , the output facet 131 and the waveguide optical axis 401 , but adapted to receive light rather than output light.
- PIC 700 further comprises other optical components, for example which may include, but are not limited to, optical modulators, and the like, and that the waveguide 729 may be in optical communication with such optical components, such that the waveguide 729 guides light, received at the input facet 731 , to such optical components, for modulation thereof, and the like.
- optical components for example which may include, but are not limited to, optical modulators, and the like, and that the waveguide 729 may be in optical communication with such optical components, such that the waveguide 729 guides light, received at the input facet 731 , to such optical components, for modulation thereof, and the like.
- the device 100 is being operated via the power supply 601 during the locating, such that the light 603 is being emitted from the output facet 131 , as described above.
- Such operation may also cause the waveguide 129 to at least partially emit light from surfaces thereof such that the waveguide 129 more visible to the imaging system 712 as compared to when the device 100 is not being operated.
- such operation may also cause the waveguide 129 to at least partially guide light to a photodetector and/or power detector and/or light detector, and the like, such that the output signal thereof can be used to aid in aligning the output facet 131 to the input facet 731 .
- the device 100 is not operated during the locating.
- the imaging system 712 is generally positioned to image a face of the protruding region 133 where the waveguide 129 (e.g. and the output face 131 ) and the alignment features 135 (e.g. when present) are located and, for example, a face of the PIC 700 where the waveguide 129 and the edge 741 of the cavity 701 (e.g. and the input facet 731 ) are located.
- the imaging system 712 may comprise any suitable imaging system including, but not limited to, a machine vision system which may be in communication with a feedback system 760 , that is also in communication with the robotic device 710 , and/or a controller thereof.
- the robotic device 710 may be controlled in a feedback loop, with images from the imaging system 712 used to locate the body 121 of the laser 103 in the cavity 701 such that the carrier 101 is located at the surface 702 (and/or a pedestal and/or recess at the surface 702 of the PIC 700 ) and the laser 103 is located in a cavity 701 of the PIC 700 , such that respective optical axes 401 , 751 of the output facet 131 and the input facet 731 are about aligned.
- the goal of locating the device 100 at the PIC 700 is to align the axes 401 , 751 and/or the waveguides 129 , 729 (and/or the facets 131 , 731 ) such that light exiting the output facet 131 enters the input facet 731 .
- the surface 702 may also include pedestals and/or recesses onto which (and/or into which) the carrier 101 is located and/or which mate with respective features at the carrier 101 .
- the alignment of the optical axes 401 , 751 , etc. may be detected via the imaging system 712 imaging the protruding region 133 during attachment of the carrier 101 attached to the surface 702 (e.g. via a polymer adhesive and/or a thermoset adhesive and/or an ultraviolet (UV) adhesive and the like.
- the imaging system 712 imaging the protruding region 133 during attachment of the carrier 101 attached to the surface 702 (e.g. via a polymer adhesive and/or a thermoset adhesive and/or an ultraviolet (UV) adhesive and the like.
- UV ultraviolet
- the robotic device 710 may be used to move the device 100 to more precisely align the respective optical axes 401 , 751 , and the like, using the feedback system 760 which is generally configured to assist with determining when the optical axes 401 , 751 and the like, are aligned.
- the imaging system 712 e.g. machine vision system
- the imaging system 712 may be used to image one or more of the protruding region 133 and the alignment features 135 relative to the waveguide 729 of the PIC 700 , during the moving of the laser device 100 to determine when the optical axes 401 , 751 and the like are more precisely aligned.
- the feedback system 760 which may comprise any suitable combination of processers, controllers, memories, and the like, may be configured to determine a position of the alignment features 135 relative to features of the PIC 700 that correspond to the optical axes 401 , 751 and the like being more precisely aligned.
- the feedback system 760 may rely on images of the alignment features 135 to position and/or locate the device 100 relative to the PIC 700 .
- the more precise alignment may also occur during operation of the laser device 100 such that, when the optical axes 401 , 751 , and the like, being more precisely aligned, the waveguide 729 may become more visible to the imaging system 712 due to the light 603 entering the waveguide 729 more precisely.
- the feedback system 760 may further comprise one or more of a power measurement device and a light measurement device (not depicted) in optical communication with the input facet 731 via the waveguide 729 , for example via an optical tap, and the like, located at the waveguide.
- a power measurement device and a light measurement device in optical communication with the input facet 731 via the waveguide 729 , for example via an optical tap, and the like, located at the waveguide.
- the feedback system 760 may determine that the optical axes 401 , 751 and the like are more precisely aligned by determining that an output signal of the power measurement device and/or the light measurement device is about maximized at a given location of the laser device 100 relative to the PIC 700 (e.g. and enablement of such maximizing by the present specification may be an advantage over soldering during alignment). In some examples, more precise positioning may be facilitated with an index matching polymer fluid placed between the output fact 131 and input facet 731 (e.g. to facilitate transfer of light therebetween).
- the device 100 in a first step, is positioned at the surface 702 with the laser 103 located in the cavity 701 , and the facets 131 , 731 about facing each other and/or facing in opposite directions, but without initial regard to precision of the alignment of the optical axes 401 , 751 and the like; in a second step, the device 100 is more further positioned to more precisely align the optical axes 401 , 751 and the like.
- physical mating surfaces of the PIC 700 and the device 100 are not necessarily used to align the optical axes 401 , 751 but rather the optical axes 401 , 751 may be aligned in the second step.
- the physical mating surfaces of the PIC 700 and the device 100 may be used to initially position the device 100 at the surface 702
- the robotic device 710 , and the like may be used to locate the device 100 relative to the PIC 700 (e.g. whether the carrier 101 is touching the surface 702 , or not) and polymer adhesive, and the like, may be used to fix the device 100 in place relative to the PIC 700 (e.g. with respective mating surfaces being separated).
- Such “vertical” positioning may be performed in a manner that aligns the optical axes 401 , 751 , and the like, and/or maximizes light from the output facet 131 into the input facet 731 , and/or maximized light detected by a power and/or light measurement device, as described above.
- FIG. 8 depicts an end view of the device 100 (e.g. similar to the view of FIG. 5 , but with the device 100 flipped), and with the laser 103 located in the cavity 701 of the PIC 700 (which is depicted schematically without the waveguide 729 , etc.); in other words, in FIG. 8 a first step, of positioning the device 100 at the surface 702 , with the laser 103 located in the cavity 701 , and the facets 131 , 731 about facing each other, but without initial regard to precision of the alignment of the optical axes 401 , 751 and/or the facets 131 , 731 , has occurred.
- the robotic device 710 may then move the device 100 side-to-side relative to the surface 702 and/or the cavity 701 , as represented by the arrows 801 , until the more precise alignment is achieved, as described above. Similarly, the robotic device 710 may move the device 100 vertically relative to the surface 702 and/or the cavity 701 (e.g. towards and away from the surface 702 and/or the cavity 701 ), as represented by the double-ended arrow 802 .
- FIG. 9 and FIG. 10 respectively depict a schematic side view of the device 100 and the PIC 700 and a top view of the device 100 and the PIC 700 .
- the view in FIG. 9 is similar to the view in FIG. 2 , however some components of the device 100 and the PIC 700 are omitted for simplicity and visual clarity, but they are nonetheless understood to be present.
- FIG. 9 depicts the device 100 with the carrier 101 located at the surface 702 (and/or a mating reference surface which may or may not be the same as the surface 702 ) of the PIC 700 and the laser 103 located in the cavity 701 .
- the PIC 700 is depicted in cross-section to show the relative locations of the carrier 101 and the laser 103 relative to the surface 702 and the cavity 701 (e.g. the PIC 700 is depicted through a plane perpendicular to the surface 702 ). Also depicted in FIG. 9 and FIG.
- FIG. 10 is a plane 903 of the PIC 700 which includes the waveguide optical axis 751 of the waveguide 729 and which is about perpendicular to the input facet 731 ; the plane 903 is depicted in a side view in FIG. 9 and in a top view in FIG. 10 .
- the plane 403 of the device 100 is also depicted in a side view in FIG. 9 and in a top view in FIG. 10 . Comparing FIG. 9 and FIG. 10 with FIG. 7 , it is understood that the plane 903 is aligned with the plane 403 of the device, that includes the respective waveguide optical axis 401 of the respective waveguide 129 and is about perpendicular to the output facet 131 .
- the more of pedestals and recesses of the device 100 are generally selected to be of a size and configuration to locate the output facet 131 and the waveguide optical axis 401 at the plane 403 that aligns with the plane 903 when the carrier 101 is attached to the PIC 700 .
- the term “align” and/or “precisely align” as used with respect to the planes 403 , 903 may be understood to mean that the planes 403 , 903 are positioned in a same plane and/or coplanar with one another.
- the one or more of the pedestals and the recesses e.g.
- the pedestals 137 are configured locate the output facet 131 and the waveguide optical axis 401 at the plane 403 , relative to a surface (e.g. at the second side 112 ) of the carrier 101 that is attached to the PIC 700 .
- FIG. 10 further shows that the waveguides 129 , 729 are also aligned when the planes 403 , 903 are aligned.
- the term “precisely align” as used with respect to the waveguides 129 , 729 may be understood to mean that the waveguides 129 , 729 are positioned in a same line and/or colinear with one another.
- the term “align” as used with respect to the waveguides 129 , 729 may be understood to mean that the waveguides 129 , 729 are positioned about parallel to each other with the facets 131 , 731 facing in opposite directions (e.g.
- the term “align” as used with respect to the waveguides 129 , 729 may be further understood to mean that the waveguides 129 , 729 are positioned about parallel to each other with the facets 131 , 731 positioned such that a portion of light emitted from the output facet 131 enters the input facet 731 (e.g. but which may not be maximized).
- the planes 403 , 903 may comprise optical planes which are referenced to and/or correlative with datum reference planes and/or semiconductor-based (e.g. as they may be formed and/or references to semiconductor surfaces of the device 100 and the PIC 700 ) datum reference planes, at both the laser assembly device 100 and the PIC 700 ; such datum reference planes may be located at mating surfaces of the laser assembly device 100 such that, when aligned, the respective planes 403 , 903 align.
- datum reference planes may be located at mating surfaces of the laser assembly device 100 such that, when aligned, the respective planes 403 , 903 align.
- the planes 403 , 903 may comprise vertical optical planes correlated to semiconductor-based datum reference planes at both the PIC 700 and laser assembly 100 ; when the laser assembly 100 is flipped and brought into contact with the PIC 700 , these physical datum reference planes mate, which may result in the optical planes 403 , 903 being aligned.
- the facets 131 , 731 are also aligned when the planes 403 , 903 are aligned.
- the term “precisely align” as used with respect to the facets 131 , 731 may be understood to mean that the facets 131 , 731 are positioned to maximize light emitted from the output facet 131 into the input facet 731 .
- the term “align” as used with respect to the facets 131 , 731 may be understood to mean that the facets 131 , 731 are positioned such that a portion of light emitted from the output facet 131 enters the input facet 731 (e.g. but which may not be maximized).
- the facets 131 , 731 when the facets 131 , 731 are precisely aligned, more light may enter the input facet 731 from the output facet 131 as compared to when facets 131 , 731 are initially aligned. However, the initial alignment may result in the facets 131 , 731 (and/or the waveguides 129 , 729 ) being precisely aligned.
- the carrier 101 has been attached to the surface 702 of the PIC 700 using an adhesive 1002 , and the like, for example along two sides of the carrier 101 adjacent the surface 702 .
- the adhesive 1002 may be located at any suitable location that attaches the carrier 101 to the surface 702 of the PIC 700 .
- the adhesive 1002 may comprise any suitable polymer adhesive compatible with the device 100 and the PIC 700 and further compatible with an environment in which the combination of the device 100 and the PIC 700 are to be deployed (e.g. in a telecommunications system, and the like).
- the adhesive 1002 may comprise comprises an ultra-violet (UV) adhesive a thermoset adhesive, and the like, however any suitable adhesive and/or polymer adhesive is within the scope of the present specification.
- soldering may be used to attach the carrier 101 to the surface 702 of the PIC 700 .
- the adhesive 1002 may be dispensed automatically using in response to the feedback system 760 determining that the device 100 and the PIC 700 are aligned and/or more precisely aligned, as described herein, for example using any suitable adhesive dispensing system which may be controlled by the feedback system 760 , and the like.
- the use of the adhesive 1002 obviates soldering of the device 100 to the PIC 700 which may reduce damage and/or increase yield (e.g. relative to when soldering is used), however the present specification does not exclude use of solder to attach the device 100 to the PIC 700 (e.g. solder may be used to attach the carrier 101 to the surface 702 of the PIC 700 .
- the facets 131 , 731 may be optically connected using polymer waveguide and/or a three-dimensional (3D) printed polymer waveguide, and the like. For example, attention is next directed to FIG.
- a 3D printed polymer waveguide has been used to optically connect the output facet 131 and the input facet 731 such that light emitted from the output facet 131 is conveyed to the input facet 731 via the polymer waveguide 1101 .
- any suitable optical coupling device may be used to couple the facets 131 , 731 including, but not limited to, evanescent waveguides, tapered waveguides, and/or any other suitable waveguide, and the like.
- the combination of the device 100 and the PIC 700 may form an optical device which may be used with a telecommunication system, and the like.
- an optical device generally comprises: a photonic integrated circuit (PIC) 700 including a waveguide 729 , an input facet 731 (e.g.
- a laser device 100 comprising: a carrier 101 comprising: opposing sides 111 , 112 joined by an edge 113 ; through-carrier-vias (TCVs) 115 between the opposing sides 111 , 112 , the TCVs 115 including electrical contacts 117 therethrough; and a laser 103 attached to a given side 112 of the opposing sides 111 , 112 of the carrier 101 , the laser 103 comprising: a body 121 supporting components of the laser 103 ; a lasing device 123 configured to produce light 603 for the PIC 700 , the lasing device 123 located between the given side 112 of the carrier 101 and the body 121 ; respective electrical connections 127 from the lasing device 123 to the electrical contacts 117 of the TCVs 115 ; and an output facet 131 (e.g.
- an output portion and respective waveguide 129 configured to convey the light 603 from the lasing device 123 out of the laser 103 , a protruding region 133 of the body 121 , supporting the output facet, 131 and the respective waveguide 129 , protruding the edge of the carrier 101 , the body 121 otherwise having a smaller footprint than the carrier 101 , the body 121 located in the cavity 701 of the PIC 700 with the output facet 131 and the respective waveguide 129 respectively aligned with the input facet 731 and the waveguide 729 of the PIC 700 , the carrier 101 attached to the PIC 700 , the carrier 101 supporting the body 121 in the cavity 701 .
- Examples of the optical device that includes the laser device 100 and the PIC 700 are shown in FIG. 9 , FIG. 10 and FIG. 11 .
- electrical connections to the assembly 100 can be made to the electrical contacts 117 using one or more of bonded wire, conductive adhesive, contact pins, solder, and the like, for example to electrically connect the assembly 100 to the PIC 700 and/or another device which operates the laser 103 during operation of an optical device into which the assembly 100 and the PIC 700 are incorporated.
- a first plane 903 of the PIC 700 that includes a waveguide optical axis 751 of the waveguide 729 and may be about perpendicular to the input facet 731 , may be aligned with a second plane 403 of the body 121 , that includes a respective waveguide optical axis 401 of the respective waveguide 129 and is about perpendicular to the output facet 131 .
- a first plane 903 of the PIC 700 may include a waveguide optical axis 751 of the waveguide 729 , and may be about perpendicular to the input facet 731 , and the optical device may further comprise, at one or more of the given side 112 of the carrier 101 , and a respective side 125 of the body 121 attached to the given side 112 , one or more of pedestals (e.g. pedestals 137 ) and recesses, configured to locate the waveguide optical axis 401 at a second plane 403 that aligns with the first plane 903 when the carrier 101 is attached to the PIC 700 , the second plane 403 being about perpendicular to the output facet 131 .
- pedestals e.g. pedestals 137
- one or more of the pedestals and the recesses may locate the output facet 131 and the waveguide optical axis 401 at the second plane 403 relative to a surface (e.g. at the side 112 ) of the carrier 101 that is attached to the PIC 700 .
- a combination of a laser and a carrier may include a region (e.g. a visible region) which is visible to an external vision system and that includes an output facet of the laser, as well as a portion of a waveguide from a lasing device of the laser to the output facet, and allows the laser to be more easily positioned at a surface of a PIC.
- a visible region includes the protruding region 133
- such a visible region may alternatively be achieved by “flipping” the laser 103 relative to carrier 101 (e.g. as described in more detail below with respect to FIG. 13 ).
- a method for assembling a device that includes a carrier and a laser with a visible region, with a PIC is next described using the device 100 and the PIC 700 as an example.
- FIG. 12 depicts an example method 1200 of manufacture of an optical device which may be performed by the components described herein.
- the method 1200 may be performed by other suitable components.
- the laser device 100 is burned-in.
- the laser device 100 comprises: a laser 103 attached to a carrier 101 , a visible region (e.g. the protruding region 133 ) of the laser 103 that includes an output facet 131 and at least a portion of a waveguide 129 configured to convey light out of the laser 103 , the visible region being visible to an imaging system (e.g. the imaging system 712 ) external to the laser device 100 .
- an imaging system e.g. the imaging system 712
- the burning-in may occur via the power supply 601 and may be performed by placing the laser device 100 in a burn-in rig, and the like, that includes connections to the power supply 601 that connect to the electrical contacts 117 ; the burning-in may comprise monitoring the laser 103 (e.g. light emitted therefrom) and/or the burning-in may comprise operating the laser 103 via the power supply 601 according to a predetermined protocol to test for failure and/or life, and the like.
- the laser device 100 is positioned at a surface 702 of the PIC 700 , using an imaging system 712 and/or a robotic device 710 such that respective optical axes 401 , 751 (e.g. of the output facet 131 and an input facet 731 of a waveguide 729 of the PIC 700 ), are about aligned.
- the laser device 100 may be positioned at a surface 702 of the PIC 700 such that the carrier 101 is located at the surface 702 and the laser 103 is located in a cavity 701 of the PIC 700 , as described above, such that such that respective optical axes 401 , 751 are about aligned.
- the laser device 100 may be further positioned to more precisely align the respective optical axes 401 , 751 (e.g. of the output facet 131 and the input facet 731 ) using the feedback system 760 , as well as using the imaging system 712 and/or the robotic device 710 .
- the carrier 101 is attached to the surface 702 of the PIC 700 .
- the carrier 101 may be attached to the surface 702 of the PIC 700 using the adhesive 1002 , a polymer adhesive, a UV adhesive, a thermoset adhesive, and the like.
- the block 1208 may include curing the UV adhesive using UV light.
- the block 1208 may include curing the thermoset adhesive using heat.
- the block 1208 may include attaching carrier 101 to the surface 702 of the PIC 700 using solder.
- the method 1200 may be performed in an automated manner.
- the method 1200 may further comprise: more precisely align the respective optical axes 401 , 751 of the output facet 131 and the input facet 731 using the feedback system 760 configured to assist with determining when the output facet 131 and the input facet 731 are aligned; and in response to determining, using the feedback system 760 , that the output facet 131 and the input facet 731 are more precisely aligned, attaching (e.g. at the block 1208 ) the carrier 101 to the surface 702 of the PIC 700 using the polymer adhesive 1002 .
- the feedback system 760 may determine that the output facet 131 and the input facet 731 are more precisely aligned when the waveguides 129 , 729 are co-linear, and the like based on images from the imaging system 712 .
- the feedback system 760 may include the imaging system 712 , and/or the feedback system 760 may be in communication with the imaging system 712 .
- the imaging system 712 may comprise a machine vision system positioned to image one or more of the visible region (e.g. the protruding region 133 ) and the alignment features 135 on the visible region (e.g. the protruding region 133 ), relative to the waveguide 729 of the PIC 700 .
- the method 1200 may further comprise imaging, using the machine vision system, one or more of the visible region (e.g.
- the feedback system 760 and/or the imaging system 712 may be configured to determine that when the alignment features 135 and/or the waveguide 129 are located a given position relative to the waveguide 729 , the facets 131 , 731 are aligned and/or more precisely aligned.
- the method 1200 may further comprise operating the laser device 100 , during the moving of the laser device 100 (e.g. at the block 1204 and/or the block 1206 ) to assist the machine vision system and/or the imaging system 712 with imaging one or more of the visible region (e.g. the protruding region 133 ) and the alignment features 135 relative to the waveguide 729 of the PIC.
- operating the laser device 100 during the moving of the laser device 100 may assist the machine vision system and/or the imaging system 712 with determining when the light 603 exiting the output facet 131 is entering the input facet 731 (e.g. due to a reduction in light scattering and the like, and or via the waveguide 729 emitting a portion of the light 603 travelling through the waveguide 729 ).
- the visible region (e.g. the protruding region 133 ) includes the alignment features 135 .
- the method 1200 may further comprise: imaging, using the imaging system 712 , the alignment features 135 to assist with one or more of: positioning (e.g. at the block 1204 ), using the imaging system 712 and/or the robotic device 710 , the laser device 100 at the surface of the PIC 700 ; and moving (e.g. at the block 1206 ), using the imaging system 712 and/or the robotic device 710 , the laser device 100 to more precisely align the output facet 131 with the input facet 731 .
- the feedback system 760 and/or the imaging system 712 may be configured to determine that when the alignment features 135 and/or waveguide 129 are located a given position relative to the waveguide 729 , the facets 131 , 731 are aligned and/or more precisely aligned.
- the feedback system 760 may comprise one or more of a power measurement device and a light measurement device in optical communication with the input facet 731 via the waveguide 729 ; in these examples, the method 1200 may further comprise determining, using the feedback system 760 , that the respective optical axes 401 , 751 are more precisely aligned: determining that an output signal of one or more of the power measurement device and the light measurement device is about maximized at a given location of the laser device relative to the PIC.
- the block 1206 may be omitted and the method 1200 may further comprise using a polymer waveguide 1101 to optically connect the output facet 131 to the input facet 731 .
- any suitable device and/or material may be used to form the polymer waveguide 1101 .
- polymer waveguides may be used in combination with attaching laser devices to a PIC in other configurations that may not include a cavity.
- FIG. 13 schematically depicts a laser device 1300 (and/or a laser assembly 1300 , and the like) comprising a carrier 1301 and a laser 1303 attached thereto; however, in contrast to the carrier 101 and the laser 103 , the laser 1303 is attached to the carrier 1301 with a lasing device 1323 , as well as a waveguide 1329 and a respective output facet 1331 (e.g. an output portion), at a side opposite the carrier 1301 .
- a laser device 1300 and/or a laser assembly 1300 , and the like
- the laser 1303 is attached to the carrier 1301 with a lasing device 1323 , as well as a waveguide 1329 and a respective output facet 1331 (e.g. an output portion), at a side opposite the carrier 1301 .
- the laser device 1300 may be similar to, and/or the same as, the laser device 100 . While details of the carrier 1301 and the laser 1303 are not depicted, it is understood that the laser 1303 includes a lasing device similar to the lasing device 123 , and the like.
- the device 1300 is attached to a surface of a PIC 1340 , for example using an adhesive, and the like, at a side of the carrier 1301 opposite that of the laser 1303 .
- the laser 1303 is not located in a cavity of the PIC 1340 ; indeed, as depicted, the PIC 1340 does not include a cavity similar to the cavity 701 .
- the side of the laser 1303 that includes the waveguide 1329 and a respective output facet 1331 may comprise a visible region, which may be used to position and/or align the device 1300 at the PIC 1340 , as described above with respect to the method 1200 .
- the visible region may include alignment features, similar to the alignment features 135 , as described above.
- the laser 1303 may be burned-in prior to attachment to the PIC 1340 as described above.
- the PIC 1340 comprises a waveguide 1339 and a corresponding input facet 1341 (e.g. an input portion), which may be respectively similar to the waveguide 729 and the input facet 731 , however the waveguide 1339 and the input facet 1341 are not located at a cavity.
- the facets 1331 , 1341 are facing in opposite directions, but are not otherwise aligned; furthermore, the facets 1331 , 1341 may be at any suitable angle, similar as described above with respect to the facets 131 , 731 .
- the facets 1331 , 1341 are in optical communication via a polymer waveguide 1351 (e.g. a 3D printed polymer waveguide), such that light exiting the output facet 1331 is conveyed to the input facet 1341 via the polymer waveguide 1351 .
- any suitable optical coupling device may be used to couple the facets 1331 , 1341 including, but not limited to, evanescent waveguides, tapered waveguides, and/or any other suitable waveguide, and the like.
- the device 1300 may be located at the PIC 1340 to minimize and/or reduce a distance between the facets 1331 , 1341 to minimize and/or reduce a length of the polymer waveguide 1351 .
- the device 1300 may be fabricated and/or burned-in (and/or screened by testing and/or tested) prior to attachment to the PIC 1340 , attached to the PIC 1340 and the polymer waveguide 1351 may be attached between the facets 1331 , 1341 to optically connect the facets 1331 , 1341 .
- the device 1300 may include alignment features (e.g. similar to the alignment features 135 and adjacent the waveguide 1329 at a surface visible to an imaging system) to assist with positioning device 1300 at the PIC 1340 .
- electrical connections to the assembly 1300 can be made to the electrical contacts (e.g.
- elements may be described as “configured to” perform one or more functions or “configured for” such functions.
- an element that is configured to perform or configured for performing a function is enabled to perform the function, or is suitable for performing the function, or is adapted to perform the function, or is operable to perform the function, or is otherwise capable of performing the function.
- the functionality of devices and/or methods and/or processes described herein can be implemented using pre-programmed hardware or firmware elements (e.g., application specific integrated circuits (ASICs), electrically erasable programmable read-only memories (EEPROMs), etc.), or other related components.
- ASICs application specific integrated circuits
- EEPROMs electrically erasable programmable read-only memories
- the functionality of the devices and/or methods and/or processes described herein can be achieved using a computing apparatus that has access to a code memory (not shown) which stores computer-readable program code for operation of the computing apparatus.
- the computer-readable program code could be stored on a computer readable storage medium which is fixed, tangible and readable directly by these components, (e.g., removable diskette, CD-ROM, ROM, fixed disk, USB drive).
- the computer-readable program can be stored as a computer program product comprising a computer usable medium.
- a persistent storage device can comprise the computer readable program code.
- the computer-readable program code and/or computer usable medium can comprise a non-transitory computer-readable program code and/or non-transitory computer usable medium.
- the computer-readable program code could be stored remotely but transmittable to these components via a modem or other interface device connected to a network (including, without limitation, the Internet) over a transmission medium.
- the transmission medium can be either a non-mobile medium (e.g., optical and/or digital and/or analog communications lines) or a mobile medium (e.g., microwave, infrared, free-space optical or other transmission schemes) or a combination thereof.
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Abstract
A carrier laser device assembly is provided in which a visible region of a laser that includes an output portion and/or output portion of a waveguide of the laser is visible to an imaging system when the laser is attached to a carrier. The laser may be burned-in and/or tested prior to attachment to a photonic integrated circuit. The output portion and/or output portion of waveguide may be aligned with a corresponding input portion and/or input portion of a waveguide of the PIC as the laser assembly is being attached to the PIC via imaging of the visible portion by the imaging system.
Description
- Increasingly, photonic and/or silicon photonics based optical engines require multiple laser sources to support multiple lanes of data. Often, the need for a greater number of lasers is, for example, because higher optical reflection tolerance often dictates lower output power that, in turn, supports fewer channels. This high number of lasers necessitates very high single-device laser yield in the integrated optical engine because the cumulative yield is compounded by the number of devices used. Furthermore, the lowest-loss and most cost-effective assembly methods require that the laser light source is directly attached to silicon photonics.
- For a better understanding of the various examples described herein and to show more clearly how they may be carried into effect, reference will now be made, by way of example only, to the accompanying drawings in which:
-
FIG. 1 depicts a top view of an example device that includes a carrier and a laser, in accordance with some examples. -
FIG. 2 depicts a side view of the example device ofFIG. 1 , in accordance with some examples. -
FIG. 3 depicts an end view of the example device ofFIG. 1 , in accordance with some examples. -
FIG. 4 depicts a perspective view of the example device ofFIG. 1 , in accordance with some examples. -
FIG. 5 depicts an end view of the laser being attached to the carrier of example device ofFIG. 1 , in accordance with some examples. -
FIG. 6 depicts a perspective view of the example device ofFIG. 1 being tested and/or burned-in, prior to attachment to a photonic integrated circuit, in accordance with some examples. -
FIG. 7 depicts a perspective view of the example device ofFIG. 1 being positioned relative to a cavity of an example PIC, in accordance with some examples. -
FIG. 8 depicts an end view of the example device ofFIG. 1 being more precisely aligned at the PIC, in accordance with some examples. -
FIG. 9 depicts a side view of the example device ofFIG. 1 attached to the PIC with respective planes, optical axes, waveguides and facets aligned, in accordance with some examples. -
FIG. 10 depicts a top view of the example device ofFIG. 1 attached to the PIC with respective planes, optical axes, waveguides and facets aligned, in accordance with some examples. -
FIG. 11 depicts a top view of the example device ofFIG. 1 attached to the PIC in an alternative manner that uses a polymer waveguides, in accordance with some examples. -
FIG. 12 depicts a flowchart of a method for attaching the example device ofFIG. 1 to a PIC, in accordance with some examples. -
FIG. 13 depicts an alternative device that includes a carrier and a laser attached to an alternative PIC with a polymer waveguide used to optically connect facets thereof, in accordance with some examples - Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the present invention.
- The apparatus and method components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.
- Current attaching processes of laser devices to photonic integrated circuits (PICs) are known to have a significant probability of causing the laser characteristics to degrade, or of causing failure during the operating life if the laser is not burned-in prior to attachment. This is particularly true if high-temperatures, such as those used for soldering, are used in the attaching process. Parallel, non-WDM (wavelength-division multiplexing) systems, typically require that one laser per “lane” be used. For example, 100, 400 and 800G systems could require 1, 4 and 8 lasers for each optical layout. Advanced packaged solutions for monolithic single die electro-optics involve placing these lasers at an ePIC (electrical photonics integrated circuit), and possibly at an ePIC wafer. For stability and reliability, such lasers may require soldering (e.g. Au—Sn soldering), as well as a post-attach burn-in for the lasers to ensure reliability of the full multi-laser assembly. However, such post-attach burn-in may result in failure of the laser which can result in failure of the entire laser assembly. In particular, burning-in laser devices after attached to a photonic integrated circuit (PIC) is problematic due to the possibility of the laser devices failing after attachment which may lead to failure of the entire PIC, along with any previously attached lasers, and packaged assembly and hence a lowered yield in producing PIC-laser assemblies. Indeed, maximizing yield of optical engines that includes one or more lasers and a PIC is paramount for reducing cost of production, and with multiple soldered and burned-in lasers that may be required per optical engine-die, the individual assembled laser die yield becomes critical.
- One approach is to provide a flipped active region (“p-down”) soldered to a PIC die with a mode-matched facet-to-facet coupling arrangement. However, a problem with monolithic PIC die systems with flipped LD configurations, is that the soldering process takes place at the die or wafer level. The flipped laser for facet-coupling requires the solder joint to be within microns of the active region. The additional stresses and stress non-uniformity of this solder joint will impact the optical performance of the lasing device. The resulting overall yield of a device that uses multiple lasers may be catastrophically low.
- An additional problem that results in further yield related impact is optical alignment. Facet-to-facet coupling can require sub-micron level accurate placement of a laser die in the flipped arrangement while being soldered at temperatures greater than 300° C. This process can require very expensive assembly equipment, and long development times.
- Hence, provided herein is a process that allows a laser assembly to be burned-in and screened by testing after soldering (e.g. attaching a lasing device to a carrier via soldering) but before the assembly is attached to the photonics and/or silicon photonics, for example to avoid device failures after attaching the laser assembly to the photonics and/or silicon photonics.
- Also provided herein is a laser assembly that may increase yield of laser-PIC assemblies as a laser is first attached to a carrier distinct from a PIC. Dimensions and/or configurations of the carrier are selected such that the carrier is compatible with subsequent attachment to a PIC.
- Also provided herein is a technique that may reduce the machine assisted alignment requirements in which an output portion and/or output facet of a waveguide of the laser is visible when the laser is attached to the carrier. For example, dimensions and/or configurations of a combination of a laser and a carrier to which the laser is attached (e.g. a laser assembly) are selected such that an output portion and/or output facet of waveguide is not eclipsed by the carrier and/or is visible to an external vision system when the laser is attached to the carrier; hence, the output portion and/or output facet of waveguide may be aligned with a corresponding input portion and/or input facet of a waveguide of the PIC as the laser assembly is being attached to the PIC. Put another way, the output of the laser on the carrier is generally visible during the attaching of the laser assembly onto the PIC and/or is not eclipsed by the PIC.
- Also provided herein is a technique that may reduce machine assisted alignment requirements, for example by removing one of the alignment axes, using semiconductor-based datum reference planes at both the PIC and laser assembly that are correlated to vertical optical planes. When the laser assembly is flipped and brought into contact with the PIC, these physical planes mate, which may result in the optical planes being aligned.
- In particular, provided herein is a device that includes a carrier with a laser attached thereto, the laser having a region (e.g. a visible region) which is visible to an external vision system and that includes an output facet of the laser, as well as a portion of a waveguide from a lasing device of the laser to the output facet, and allows the laser to be more easily positioned at a surface of a PIC. For example, the visible region may protrude from the carrier and the laser may be positioned in a cavity of the PIC as the laser is being positioned at the surface of the PIC, with the carrier interfacing with the surface of the PIC. A method for assembling the device with the PIC is also provided that relies on the visible portion for alignment of the output facet, and the associated waveguide, with an input facet, and respective associated waveguide, of the PIC.
- In particular, an aspect of the present specification provides device comprising: a carrier comprising: a first side, a second side opposing the first side, and an edge joining the first side and the second side; through-carrier vias (TCVs) from the first side to the second side, the TCVs including electrical connections therethrough; first electrical contacts for the electrical connections at the first side; and second electrical contacts for the electrical connections at the second side; and a laser attached to the second side of the carrier, the laser comprising: a body supporting components of the laser; a lasing device configured to produce light, the lasing device located at a respective side of the body attached to the second side of the carrier; respective electrical connections from the second electrical contacts to the lasing device; and a protruding region of the body protruding the edge of the carrier, the body otherwise having a smaller footprint than the carrier; and an output portion configured to convey light from the lasing device out of the laser, the output portion located at the protruding region of the body.
- Another aspect of the present specification provides a device comprising: a photonic integrated circuit (PIC) including a waveguide, an input portion to the waveguide; and a cavity, the input portion located at an interior edge of the of the cavity; and a laser device comprising: a carrier comprising: opposing sides joined by an edge; through-carrier-vias (TCVs) between the opposing sides, the TCVs including electrical connections therethrough; and a laser attached to a given side of the opposing sides of the carrier, the laser comprising: a body supporting components of the laser; a lasing device configured to produce light for the PIC, the lasing device located between the given side of the carrier and the body; respective electrical connections from the lasing device to the electrical connections of the TCVs; and an output portion and respective waveguide configured to convey the light from the lasing device out of the laser, a protruding region of the body, supporting the output portion, and the respective waveguide, protruding the edge of the carrier, the body otherwise having a smaller footprint than the carrier, the body located in the cavity of the PIC with the output portion and the respective waveguide respectively aligned with the input portion and the waveguide of the PIC, the carrier attached to the PIC, the carrier supporting the body in the cavity.
- Yet another aspect of the present specification provides a method comprising: burning-in a laser device, the laser device comprising: a laser attached to a carrier, a visible region of the laser, that includes an output portion and at least a portion of a waveguide configured to convey light out of the laser, the visible region being visible to an imaging system external to the laser device; positioning, using one or more of the imaging system and a robotic device, the laser device at a surface of a photonic integrated circuit (PIC) such that respective optical axes of the output portion and an input portion of a waveguide of the PIC, are about aligned; and attaching the carrier to the surface of the PIC.
- Yet another aspect of the present specification provides a device comprising: a photonic integrated circuit (PIC) including a waveguide and an input portion to the waveguide; and a laser device attached to the PIC, the laser device comprising: a carrier; a laser attached to the carrier, the laser comprising: a lasing device, a respective waveguide, an output portion, and a visible region of the laser that includes the output portion and at least a portion of the waveguide configured to convey light out of the laser via the output portion to the input portion of the PIC, the output portion and the input portion being optically coupled via an optical coupling device, the visible region being visible to an imaging system external to the laser device.
- While reference is made hereafter to “facets”, for example of an output facet and an input facet of waveguides, such terms may be interchangeably referred, hereafter, respectively, as an output portion (e.g. of a waveguide) and an input portion (e.g. of a waveguide), though the terms output portion and input portion (e.g. of a waveguide) are understood to encompass other structures and/or configurations for emitting or receiving light at a waveguide (e.g. other than facets). For example, optical coupling between waveguides, described as occurring via “facets”, may alternatively occur via at any suitable input portions and output portions of the waveguides, including, but not limited to, evanescent coupling between a polymer waveguide (and/or a three-dimensional printed polymer waveguide) and a laser waveguide and/or PIC waveguide.
- Attention is directed to
FIG. 1 ,FIG. 2 , andFIG. 3 which respectively depict a top view, a side-cross-sectional view (e.g. through a line A-A ofFIG. 1 ), and an end view of a laser device 100 (interchangeably referred to hereafter as thedevice 100 and/or alaser device assembly 100 and/or an assembly 100). - The
device 100 comprises acarrier 101 and alaser 103. As will be explained in more detail below, thelaser device 103 is attached to, and/or assembled with, thecarrier 101 andlaser device assembly 100 burned-in (e.g. and tested) prior to attachment to a PIC. - The
carrier 101 generally comprises any suitable material which may include, but is not limited to, silicon, silicon nitride, and the like, and/or any other suitable material (e.g. another suitable crystalline material, a suitable ceramic and the like), etched and/or cut and/or formed and/or cleaved into a suitable shape. Hence, in a particular example, thecarrier 101 may comprise a silicon carrier. Thecarrier 101 generally acts as a mechanical support mechanism for thelaser 103 as described in more detail below. As best seen inFIG. 1 andFIG. 2 , a portion of thelaser 103 protrudes relative to the carrier 10, and components of thelaser 103 inFIG. 1 which are obscured by thecarrier 101 are depicted in outline to show relative positions thereof to the remainder of the components of thedevice 100. - The
carrier 101 generally comprises: afirst side 111, asecond side 112 opposing thefirst side 111, and anedge 113 joining thefirst side 111 and thesecond side 112. It is understood that while oneedge 113 joining thefirst side 111 and thesecond side 112 is numbered and described herein, other edges join thesides sides edge 113. However, thecarrier 101 may have any suitable shape and hence any suitable number of edges. - The
carrier 101 further comprises through-carrier vias (TCVs) 115-1, 115-2 (e.g. interchangeably referred to herein, collectively, as TCVs 115 and, generically, as a TCV 115) from thefirst side 111 to thesecond side 112. InFIG. 2 andFIG. 3 , the TCVs 115 are depicted in outline indicating that they are located inside thecarrier 101. - When the
carrier 101 comprises a silicon carrier, the TCVs may comprise through-silicon vias (TSVs). The TCVs generally including electrical connections therethrough; for example, the TCVs may be filled with conducting material, such as aluminum, gold, and the like. Thecarrier 101 further comprises first electrical contacts 117-1, 117-2 (e.g. electrical contacts 117 and/or an electrical contact 117) for the electrical connections at thefirst side 111; and second electrical contacts 127-1, 127-2 (e.g.electrical contacts 127 and/or an electrical contact 127) for the electrical connections at thesecond side 112. As best seen inFIG. 3 , theelectrical contacts 127 are electrically connected to respective laser electrical connections 128-1, 128-2 (e.g. electrical connections 128 and/or an electrical connection 128 to the lasing device 123) via respective solder connections 119-1, 119-2 (e.g. solder connections 119 and/or a solder connection 119), for example during assembly of thelaser 103 to thecarrier 101. As also best seen inFIG. 3 , thecarrier 101 further comprises arecess 120 at thesecond side 112, and the solder connections 119 may be located in therecess 120 at thesecond side 112 and similarly a portion of theelectrical contacts 127 that connect to the solder connections 119 may also be located in therecess 120 at thesecond side 112. However the electrical connections 128 and theelectrical contacts 127 may be electrically connected in any suitable manner (e.g. with electrical connections different from solder connections, for example bonded wire, conductive adhesive, contact pins, and the like). - It is understood that the TCVs 115 may not (e.g. as depicted) be aligned with the electrical connections 128 and/or solder connections 119 and hence, the
electrical contacts 127 may include electrical traces and the like between an end of the electrical connections in the TCVs 115 at thesecond side 112 and electrical connections 128 and/or the solder connections 119. Hence, when power, voltage, and the like, are supplied to the electrical contacts 117, the power, voltage, and the like are fed to corresponding electrical connections 128 via the electrical connections in the TCVs 115, corresponding electrical contacts 127 (e.g. and corresponding traces thereof), and corresponding solder connections 119, and the like. For example, the electrical contact 117-1 and the electrical connection 128-1 are electrically connected, and the electrical contact 117-2 and the electrical connection 128-2 are electrically connected. The electrical contacts 117, and theelectrical contacts 127 may be formed from a same and/or similar material as the electrical connections in the TCVs 115, however the electrical contacts 117 are of a shape and size for connecting a power and/or voltage source thereto, and theelectrical contacts 127 are of a shape and size such that corresponding electrical connections 128 of thelaser 103 may be soldered toelectrical contacts 127 via the solder connections 119. In some examples, the electrical connection 128-1 comprises an “N” electrical connection to thelasing device 123, and the electrical connection 128-2 comprises a “P” electrical connection to thelasing device 123. - As best seen in
FIG. 1 andFIG. 2 , thelaser 103 is generally attached to thesecond side 112 of thecarrier 101, for example as described in more detail below (e.g. via soldering using the solder connections 119, and/or other suitable attachment mechanisms and/or material). In particular, thelaser 103 comprises: abody 121 supporting components of thelaser 103; and alasing device 123 configured to produce light, thelasing device 123 located at arespective side 125 of thebody 121 attached to thesecond side 112 of thecarrier 101. In particular, as described in more detail below, thelasing device 123 may be combined with and/or at least partially include awaveguide 129 and/or at least partially be combined with thewaveguide 129, and/or thelasing device 123 and thewaveguide 129 may be coincident such that thewaveguide 129 guides light from thelasing device 123 to anoutput facet 131. In some examples, Thelasing device 123 may include an active guided region and a passive waveguiding region (e.g. the waveguide 129), where a lasing gain region of thelasing device 123 makes up only a portion of a lengthwise section of the lasing device 123 (e.g. thewaveguide 129 may comprise a front passive waveguide section of the lasing device 123); regardless thelasing device 123 may generally include an active lasing section that outputs light to an active guided region, which guides light to the passive region, and/or to thewaveguide 129. - The
lasing device 123 may comprise anysuitable lasing device 123 and may be formed at thebody 121 and/or thewaveguide 129 using any suitable process. For example, thebody 121 may comprise InP (Indium Phosphide) that is p-doped at the side 125 (e.g. and n-doped at an opposite side), and thelasing device 123 may comprise an InP lasing device formed at the p-doped side of theInP body 121. As such, thelaser 103 may be referred to as an InP P-Up laser and/or assembly, and the like. - While not described in detail, it is understood that the
laser 103 may be fabricated using techniques familiar to those of skill in the art including, but not limited to photolithography, etching, and the like (e.g. beginning with doped InP and the like). - As has already been described, the
laser 103 further comprises respective electrical connections 128 fromelectrical contacts 127 to the lasing device 123 (e.g. via the solder connections 119). For example, the electrical contact 127-1 may be soldered to the electrical connection 128-1 via the solder connection 119-1, and the electrical contact 127-2 may be soldered to the electrical connection 128-2 via the solder connection 119-2. Hence, thelaser 103 may be at least partially attached to thecarrier 101 via soldering of theelectrical contacts 127 and the electrical connection 128 via respective solder connections 119. However, thelaser 103 may be at least partially attached to thecarrier 101 via any suitable technique and/or material including, but not limited to: bonded wire, conductive adhesive, contact pins, solder and the like. - Put another way, electrical contacts 117 and/or the electrical contacts 127 (e.g. electrical traces thereof) are connected to electrical components of the
lasing device 123 which cause thelasing device 123 to lase and emit light. Hence, the electrical contact 117-1 may be electrically connected to an “N” electrical connection 128-1 of thelasing device 123 via the TCV 115-1, the electrical contact 127-1, and the solder connection 119-1, and the electrical contact 117-2 may be electrically connected to a “P” electrical connection 128-2 of thelasing device 123 via the TCV 115-2, the electrical contact 127-2, and the solder connection 119-2, and thelasing device 123 may hence be operated via the electrical contacts 117. - As has already been described, the
laser 103 further comprises awaveguide 129 which conveys light from thelasing device 123 to theoutput facet 131 such that the light from thelasing device 123 may exit thelaser 103. As has already been described, thewaveguide 129 may comprise a passive waveguide region of thelasing device 123. As depicted, theoutput facet 131 may generally be about perpendicular to thesecond side 112 of thecarrier 101 and is configured to convey light from thelasing device 123 out of the laser 103 (e.g. via the waveguide 129). However, while theoutput facet 131 is depicted as perpendicular to thesecond side 112 of thecarrier 101, theoutput facet 131 may be at any suitable angle to the second side 112 (e.g. in a range of about 0° to about 8° (e.g. off of perpendicular) and/or any other suitable angle). - As depicted, the
body 121 generally comprises aprotruding region 133, supporting theoutput facet 131 and protruding theedge 113 of thecarrier 101. Theprotruding region 133 may alternatively be referred to using the term “visible region”, as described throughout the present specification. As best seen inFIG. 1 , thebody 121 and/or thelaser 103 otherwise has a smaller footprint than thecarrier 101. As will be explained in more detail below, thebody 121 of thelaser 103 is generally configured (e.g. of a suitable shape and size) to reside in a photonic integrated circuit (PIC) cavity, supported by thecarrier 101. Furthermore, as best seen inFIG. 2 , theoutput facet 131 is located at theprotruding region 133 and/or theoutput facet 131 is located at anend 132 of theprotruding region 133. - As best seen in
FIG. 1 , thedevice 100 may further comprise, at theprotruding region 133 of thelaser 103 and/or thebody 121, optional alignment features 135 configured to facilitate one or more of machine and human vision alignment of theoutput facet 131, and thecorresponding waveguide 129 of thelaser 103 which ends at theoutput facet 131, with an input facet, and respective waveguide, of a PIC to which thedevice 100 is being attached. As depicted, the alignment features 135 comprise two crosses, arranged symmetrically around thewaveguide 129, at a face of theprotruding region 133 where thewaveguide 129 is located. However, the alignment features 135 when present, may comprise any suitable marks, and the like, located at any suitable position at theprotruding region 133. Furthermore, while the alignment features 135 are depicted as symmetric, the alignment features 135 need not be symmetric; indeed, the alignment features 135 may be any suitable shape that is recognizable to an imaging system and/or a machine vision system, having suitable contrast therefor (e.g. compared to other portions of the protruding region 133), and where coordinates of the alignment features 135, with respect to an optical axis of thewaveguide 129 and/or theoutput facet 131, have been predetermined and/or are “known” and/or preconfigured at a device controlling positioning of thedevice 100 at a PIC, as described in more detail below. The alignment features 135 may be photoetched at theprotruding region 133 during fabrication of thelaser 103. - As best seen in
FIG. 2 andFIG. 3 , thedevice 100 may further comprise, at mating surfaces (e.g. surfaces of thesecond side 112 and theside 125 which mate with each other) of one or more of thecarrier 101 and thebody 121, one or more of pedestals (e.g. as depicted pedestals 137) and recesses configured to locate theoutput facet 131 and a waveguide optical axis at a given plane, parallel to thesecond side 112. For example, attention is next directed toFIG. 4 which depicts a perspective view of thedevice 100, showing an end of thedevice 100 that includes theprotruding region 133 and theoutput facet 131. As seen inFIG. 4 , theoutput facet 131 includes an end of thewaveguide 129, though theoutput facet 131 may be recessed into thebody 121 of the laser 103 (e.g. light from thelasing device 123 is generally guided by thewaveguide 129 formed at a surface of thebody 121, though the light from thelasing device 123 may further travel in thebody 121 adjacent the waveguide 129); in general, theoutput facet 131 comprises a portion of an end of theprotruding region 133 where thewaveguide 129 terminates at which light is emitted from thelasing device 123. For example, as further depicted inFIG. 4 , thelaser 103 further comprises a waveguideoptical axis 401, which may be parallel to thewaveguide 129 and/or normal (e.g. perpendicular) theoutput facet 131, however the waveguideoptical axis 401 may be at any suitable angle to thewaveguide 129 and/or theoutput facet 131. Indeed, the angle of the waveguideoptical axis 401 may at least partially depend on the angle of theoutput facet 131; in some examples, an angle the waveguideoptical axis 401 may be in a range of about 0° to about 21° (and/or at any suitable angle) due to refraction at theoutput facet 131. The waveguideoptical axis 401 generally indicates a location and direction at which light is emitted from thelaser 103. Theoutput facet 131 may be perpendicular to the waveguideoptical axis 401, or at another angle thereto (e.g. the aforementioned range of about 0° to about 8° and/or any other suitable angle). - As also depicted in
FIG. 4 , a givenplane 403 is defined by theoutput facet 131 and the waveguideoptical axis 401; for example, the givenplane 403 includes the waveguideoptical axis 401 and may be about perpendicular to the output facet 131 (e.g. when theoutput facet 131 is about perpendicular to the second side 112) and/or the givenplane 403 may be about parallel to mating surfaces of thecarrier 101 and/or thelaser device 100. Indeed, as depicted, the givenplane 403 is further parallel to thesecond side 112 of thecarrier 101. In particular, dimensions and configurations of the one or more of the pedestals (e.g. as depicted pedestals and recesses 137) and pedestals or recesses at the mating surfaces of one or more of thecarrier 101 and thebody 121 are generally selected to position the givenplane 403 at a location where, when thedevice 100 is positioned relative to a cavity of a PIC (described below), the givenplane 403 is aligned with a respective plane of the PIC (e.g. which may be about perpendicular to an input facet thereof, as described in more detail below). Put another way, the pedestals 137 (and/or recesses) generally locate the waveguide optical axis 401 (e.g. and/or theoutput facet 131 and/or theplane 403 and/or) at a given position relative to thesecond side 112 of thecarrier 101, as described above such that the waveguideoptical axis 401 is aligned with respective an waveguide optical axis (e.g. and/or input facet) of a PIC when thedevice 100 is positioned relative to a cavity of a PIC (and/or respective waveguide optical axes are aligned when thedevice 100 is positioned relative to a cavity of a PIC). - Attention is next directed to
FIG. 5 which depicts an end view of thedevice 100 as thelaser 103 is being attached to thecarrier 101. For example, thecarrier 101 and thelaser 103 may be inverted as compared toFIG. 3 , thecarrier 101 may be placed in a rig (not depicted) and/or a device for holding thecarrier 101 and the like, and thelaser 103 may be mated, and electrically connected, with thecarrier 101 for example by soldering theelectrical contacts 127 with respective electrical connections 128 to form the solder connections 119 (e.g. the soldering represented by arrows 501); the pedestals 137 (and/or recesses) generally locate the waveguide optical axis 401 (and/or theplane 403 and/or the output facet 131) at a given position relative to thesecond side 112 of thecarrier 101, as described above. - Once the
device 100 is assembled, thedevice 100 may be burned-in (e.g. and tested) by operating thelasing device 123. For example attention is next directed toFIG. 6 which depicts a perspective of thedevice 100 being burned-in (e.g. and/or tested). For example, the electrical contacts 117 are connected to apower supply 601 and thelasing device 123 is operated such that light 603 (e.g. laser light) is emitted from theoutput facet 131 along the waveguideoptical axis 401 and/or about along the output facet 131 (e.g. depending on an angle of the output facet 131). The burn-in (and/or testing) process may both stabilize operation of thelasing device 123 and test the operation of thelasing device 123. For example, during burn-in, the light 603 may be monitored for intensity and/or wavelength, and the like, and similarly power and/or voltage used to operate thelasing device 123 at thepower supply 601 may be monitored to determine whether thelasing device 123 is operating within given parameters (e.g. compatible with a PIC and/or a telecommunication system with which thedevice 100 is to be used (e.g. in combination with a PIC)). The burn-in process may continue for any suitable time, which may be determined heuristically and/or until it is determined that thelasing device 123 is operating within given parameters and/or until it is determined that thelasing device 123 is not failing. Indeed, burning-in thedevice 100, prior to attachment to a PIC, may ensure that thedevice 100 is operating within the given parameters, which may increase yield of optical devices that include a combination of thedevice 100 and a corresponding PIC (e.g. relative to burning-in after attachment to a PIC). - Attention is next directed to
FIG. 7 which depicts a perspective view of thedevice 100 being located at aPIC 700, which comprises acavity 701 in asurface 702 of thePIC 700, using a robotic device 710 (e.g. a robotic arm, and the like, as depicted holding thedevice 100 via thecarrier 101, and the like)) and animaging system 712. Thesurface 702 may comprise a fixed mating surface of the PIC 700 (e.g. to which thecarrier 101 is to be attached, as described in more detail below). It is understood that only a portion thePIC 700 is depicted, and that thePIC 700 further includes awaveguide 729, aninput facet 731 to thewaveguide 729; and thecavity 701, theinput facet 731 located at aninterior edge 741 of the of thecavity 701; theinput facet 731 may be perpendicular to the waveguideoptical axis 751 and/or at another angle thereto (e.g. similar to theoutput facet 131, in the aforementioned range of about 0° to about 8° and/or any other suitable angle). A waveguideoptical axis 751 of thewaveguide 729 and/or theinput facet 731 is also depicted. It is understood that thewaveguide 729, theinput facet 731 and the waveguideoptical axis 751 are substantially similar, respectively, to thewaveguide 129, theoutput facet 131 and the waveguideoptical axis 401, but adapted to receive light rather than output light. - While not depicted, it is understood that
PIC 700 further comprises other optical components, for example which may include, but are not limited to, optical modulators, and the like, and that thewaveguide 729 may be in optical communication with such optical components, such that thewaveguide 729 guides light, received at theinput facet 731, to such optical components, for modulation thereof, and the like. - As depicted, the
device 100 is being operated via thepower supply 601 during the locating, such that the light 603 is being emitted from theoutput facet 131, as described above. Such operation may also cause thewaveguide 129 to at least partially emit light from surfaces thereof such that thewaveguide 129 more visible to theimaging system 712 as compared to when thedevice 100 is not being operated. As another example, such operation may also cause thewaveguide 129 to at least partially guide light to a photodetector and/or power detector and/or light detector, and the like, such that the output signal thereof can be used to aid in aligning theoutput facet 131 to theinput facet 731. However, in other examples, thedevice 100 is not operated during the locating. - The
imaging system 712 is generally positioned to image a face of theprotruding region 133 where the waveguide 129 (e.g. and the output face 131) and the alignment features 135 (e.g. when present) are located and, for example, a face of thePIC 700 where thewaveguide 129 and theedge 741 of the cavity 701 (e.g. and the input facet 731) are located. Theimaging system 712 may comprise any suitable imaging system including, but not limited to, a machine vision system which may be in communication with afeedback system 760, that is also in communication with therobotic device 710, and/or a controller thereof. Therobotic device 710 may be controlled in a feedback loop, with images from theimaging system 712 used to locate thebody 121 of thelaser 103 in thecavity 701 such that thecarrier 101 is located at the surface 702 (and/or a pedestal and/or recess at thesurface 702 of the PIC 700) and thelaser 103 is located in acavity 701 of thePIC 700, such that respectiveoptical axes output facet 131 and theinput facet 731 are about aligned. Indeed, the goal of locating thedevice 100 at thePIC 700 is to align theaxes waveguides 129, 729 (and/or thefacets 131, 731) such that light exiting theoutput facet 131 enters theinput facet 731. While not depicted, thesurface 702 may also include pedestals and/or recesses onto which (and/or into which) thecarrier 101 is located and/or which mate with respective features at thecarrier 101. - In some examples, the alignment of the
optical axes imaging system 712 imaging theprotruding region 133 during attachment of thecarrier 101 attached to the surface 702 (e.g. via a polymer adhesive and/or a thermoset adhesive and/or an ultraviolet (UV) adhesive and the like. - However, in other examples, prior to attaching the
carrier 101 to thesurface 702, therobotic device 710 may be used to move thedevice 100 to more precisely align the respectiveoptical axes feedback system 760 which is generally configured to assist with determining when theoptical axes protruding region 133 and the alignment features 135 relative to thewaveguide 729 of thePIC 700, during the moving of thelaser device 100 to determine when theoptical axes feedback system 760, which may comprise any suitable combination of processers, controllers, memories, and the like, may be configured to determine a position of the alignment features 135 relative to features of thePIC 700 that correspond to theoptical axes optical axis 401 and/or theoutput facet 131, have been predetermined and/or are “known”, and may be preconfigured at thefeedback system 760, and the like, thefeedback system 760 may rely on images of the alignment features 135 to position and/or locate thedevice 100 relative to thePIC 700. - Furthermore, the more precise alignment may also occur during operation of the
laser device 100 such that, when theoptical axes waveguide 729 may become more visible to theimaging system 712 due to the light 603 entering thewaveguide 729 more precisely. - In yet another example, the
feedback system 760 may further comprise one or more of a power measurement device and a light measurement device (not depicted) in optical communication with theinput facet 731 via thewaveguide 729, for example via an optical tap, and the like, located at the waveguide. During the more precise alignment of theoptical axes feedback system 760 as therobotic device 710 moves thedevice 100. Thefeedback system 760 may determine that theoptical axes laser device 100 relative to the PIC 700 (e.g. and enablement of such maximizing by the present specification may be an advantage over soldering during alignment). In some examples, more precise positioning may be facilitated with an index matching polymer fluid placed between theoutput fact 131 and input facet 731 (e.g. to facilitate transfer of light therebetween). - Put another way, in a first step, the
device 100 is positioned at thesurface 702 with thelaser 103 located in thecavity 701, and thefacets optical axes device 100 is more further positioned to more precisely align theoptical axes PIC 700 and thedevice 100 are not necessarily used to align theoptical axes optical axes - Furthermore, in some examples, as will be described in more detail below, while the physical mating surfaces of the
PIC 700 and thedevice 100 may be used to initially position thedevice 100 at thesurface 702, therobotic device 710, and the like, may be used to locate thedevice 100 relative to the PIC 700 (e.g. whether thecarrier 101 is touching thesurface 702, or not) and polymer adhesive, and the like, may be used to fix thedevice 100 in place relative to the PIC 700 (e.g. with respective mating surfaces being separated). Such “vertical” positioning may be performed in a manner that aligns theoptical axes output facet 131 into theinput facet 731, and/or maximized light detected by a power and/or light measurement device, as described above. - For example, attention is next directed to
FIG. 8 which depicts an end view of the device 100 (e.g. similar to the view ofFIG. 5 , but with thedevice 100 flipped), and with thelaser 103 located in thecavity 701 of the PIC 700 (which is depicted schematically without thewaveguide 729, etc.); in other words, inFIG. 8 a first step, of positioning thedevice 100 at thesurface 702, with thelaser 103 located in thecavity 701, and thefacets optical axes facets robotic device 710 may then move thedevice 100 side-to-side relative to thesurface 702 and/or thecavity 701, as represented by thearrows 801, until the more precise alignment is achieved, as described above. Similarly, therobotic device 710 may move thedevice 100 vertically relative to thesurface 702 and/or the cavity 701 (e.g. towards and away from thesurface 702 and/or the cavity 701), as represented by the double-endedarrow 802. - Such precise alignment is further depicted in
FIG. 9 andFIG. 10 which respectively depict a schematic side view of thedevice 100 and thePIC 700 and a top view of thedevice 100 and thePIC 700. The view inFIG. 9 is similar to the view inFIG. 2 , however some components of thedevice 100 and thePIC 700 are omitted for simplicity and visual clarity, but they are nonetheless understood to be present. - In particular, in
FIG. 9 depicts thedevice 100 with thecarrier 101 located at the surface 702 (and/or a mating reference surface which may or may not be the same as the surface 702) of thePIC 700 and thelaser 103 located in thecavity 701. ThePIC 700 is depicted in cross-section to show the relative locations of thecarrier 101 and thelaser 103 relative to thesurface 702 and the cavity 701 (e.g. thePIC 700 is depicted through a plane perpendicular to the surface 702). Also depicted inFIG. 9 andFIG. 10 is aplane 903 of thePIC 700 which includes the waveguideoptical axis 751 of thewaveguide 729 and which is about perpendicular to theinput facet 731; theplane 903 is depicted in a side view inFIG. 9 and in a top view inFIG. 10 . Theplane 403 of thedevice 100 is also depicted in a side view inFIG. 9 and in a top view inFIG. 10 . ComparingFIG. 9 andFIG. 10 withFIG. 7 , it is understood that theplane 903 is aligned with theplane 403 of the device, that includes the respective waveguideoptical axis 401 of therespective waveguide 129 and is about perpendicular to theoutput facet 131. Hence, the more of pedestals and recesses of thedevice 100, described heretofore with reference to thepedestals 137, are generally selected to be of a size and configuration to locate theoutput facet 131 and the waveguideoptical axis 401 at theplane 403 that aligns with theplane 903 when thecarrier 101 is attached to thePIC 700. In particular, the term “align” and/or “precisely align” as used with respect to theplanes planes output facet 131 and the waveguideoptical axis 401 at theplane 403, relative to a surface (e.g. at the second side 112) of thecarrier 101 that is attached to thePIC 700. - Reference is next made to
FIG. 10 which further shows that thewaveguides planes waveguides waveguides waveguides waveguides facets facets respective axes waveguides waveguides facets output facet 131 enters the input facet 731 (e.g. but which may not be maximized). - Indeed, the
planes device 100 and the PIC 700) datum reference planes, at both thelaser assembly device 100 and thePIC 700; such datum reference planes may be located at mating surfaces of thelaser assembly device 100 such that, when aligned, therespective planes planes PIC 700 andlaser assembly 100; when thelaser assembly 100 is flipped and brought into contact with thePIC 700, these physical datum reference planes mate, which may result in theoptical planes - While not depicted in
FIG. 10 , it is understood that thefacets planes facets facets output facet 131 into theinput facet 731. However, the term “align” as used with respect to thefacets facets output facet 131 enters the input facet 731 (e.g. but which may not be maximized). Put another way, in some examples, when thefacets input facet 731 from theoutput facet 131 as compared to whenfacets facets 131, 731 (and/or thewaveguides 129, 729) being precisely aligned. - As will be explained below, in
FIG. 10 thecarrier 101 has been attached to thesurface 702 of thePIC 700 using an adhesive 1002, and the like, for example along two sides of thecarrier 101 adjacent thesurface 702. However, the adhesive 1002 may be located at any suitable location that attaches thecarrier 101 to thesurface 702 of thePIC 700. - The adhesive 1002 may comprise any suitable polymer adhesive compatible with the
device 100 and thePIC 700 and further compatible with an environment in which the combination of thedevice 100 and thePIC 700 are to be deployed (e.g. in a telecommunications system, and the like). For example, the adhesive 1002 may comprise comprises an ultra-violet (UV) adhesive a thermoset adhesive, and the like, however any suitable adhesive and/or polymer adhesive is within the scope of the present specification. In some examples, soldering may be used to attach thecarrier 101 to thesurface 702 of thePIC 700. - While not depicted, the adhesive 1002 may be dispensed automatically using in response to the
feedback system 760 determining that thedevice 100 and thePIC 700 are aligned and/or more precisely aligned, as described herein, for example using any suitable adhesive dispensing system which may be controlled by thefeedback system 760, and the like. Indeed, the use of the adhesive 1002 obviates soldering of thedevice 100 to thePIC 700 which may reduce damage and/or increase yield (e.g. relative to when soldering is used), however the present specification does not exclude use of solder to attach thedevice 100 to the PIC 700 (e.g. solder may be used to attach thecarrier 101 to thesurface 702 of thePIC 700. - However, in further examples, rather than more precisely align the
optical axes facets facets FIG. 11 which depicts an alternative example in which theplanes optical axes facets waveguides waveguides facets output facet 131 into theinput facet 731. However, a polymer waveguide 1101 (e.g. a 3D printed polymer waveguide) has been used to optically connect theoutput facet 131 and theinput facet 731 such that light emitted from theoutput facet 131 is conveyed to theinput facet 731 via thepolymer waveguide 1101. However, any suitable optical coupling device may be used to couple thefacets - Hence, in general, the combination of the
device 100 and thePIC 700 may form an optical device which may be used with a telecommunication system, and the like. Such an optical device generally comprises: a photonic integrated circuit (PIC) 700 including a waveguide 729, an input facet 731 (e.g. an input portion) to the waveguide 729; and a cavity 701, the input facet 731 located at an interior edge 741 of the of the cavity 701; and a laser device 100 comprising: a carrier 101 comprising: opposing sides 111, 112 joined by an edge 113; through-carrier-vias (TCVs) 115 between the opposing sides 111, 112, the TCVs 115 including electrical contacts 117 therethrough; and a laser 103 attached to a given side 112 of the opposing sides 111, 112 of the carrier 101, the laser 103 comprising: a body 121 supporting components of the laser 103; a lasing device 123 configured to produce light 603 for the PIC 700, the lasing device 123 located between the given side 112 of the carrier 101 and the body 121; respective electrical connections 127 from the lasing device 123 to the electrical contacts 117 of the TCVs 115; and an output facet 131 (e.g. an output portion) and respective waveguide 129 configured to convey the light 603 from the lasing device 123 out of the laser 103, a protruding region 133 of the body 121, supporting the output facet, 131 and the respective waveguide 129, protruding the edge of the carrier 101, the body 121 otherwise having a smaller footprint than the carrier 101, the body 121 located in the cavity 701 of the PIC 700 with the output facet 131 and the respective waveguide 129 respectively aligned with the input facet 731 and the waveguide 729 of the PIC 700, the carrier 101 attached to the PIC 700, the carrier 101 supporting the body 121 in the cavity 701. Examples of the optical device that includes thelaser device 100 and thePIC 700 are shown inFIG. 9 ,FIG. 10 andFIG. 11 . - It is further understood that electrical connections to the
assembly 100 can be made to the electrical contacts 117 using one or more of bonded wire, conductive adhesive, contact pins, solder, and the like, for example to electrically connect theassembly 100 to thePIC 700 and/or another device which operates thelaser 103 during operation of an optical device into which theassembly 100 and thePIC 700 are incorporated. - As has already been explained, in such an optical device, a
first plane 903 of thePIC 700, that includes a waveguideoptical axis 751 of thewaveguide 729 and may be about perpendicular to theinput facet 731, may be aligned with asecond plane 403 of thebody 121, that includes a respective waveguideoptical axis 401 of therespective waveguide 129 and is about perpendicular to theoutput facet 131. - Similarly, in such an optical device, a
first plane 903 of thePIC 700 may include a waveguideoptical axis 751 of thewaveguide 729, and may be about perpendicular to theinput facet 731, and the optical device may further comprise, at one or more of the givenside 112 of thecarrier 101, and arespective side 125 of thebody 121 attached to the givenside 112, one or more of pedestals (e.g. pedestals 137) and recesses, configured to locate the waveguideoptical axis 401 at asecond plane 403 that aligns with thefirst plane 903 when thecarrier 101 is attached to thePIC 700, thesecond plane 403 being about perpendicular to theoutput facet 131. Similarly, in such an optical device, one or more of the pedestals and the recesses may locate theoutput facet 131 and the waveguideoptical axis 401 at thesecond plane 403 relative to a surface (e.g. at the side 112) of thecarrier 101 that is attached to thePIC 700. - While the examples heretofore have been described with respect to the
waveguide 129 and theoutput facet 131 being located at theprotruding region 133, in other examples a combination of a laser and a carrier may include a region (e.g. a visible region) which is visible to an external vision system and that includes an output facet of the laser, as well as a portion of a waveguide from a lasing device of the laser to the output facet, and allows the laser to be more easily positioned at a surface of a PIC. For example, heretofore, such a visible region includes theprotruding region 133, however such a visible region may alternatively be achieved by “flipping” thelaser 103 relative to carrier 101 (e.g. as described in more detail below with respect toFIG. 13 ). A method for assembling a device that includes a carrier and a laser with a visible region, with a PIC is next described using thedevice 100 and thePIC 700 as an example. - Hence, attention is next directed to
FIG. 12 which depicts anexample method 1200 of manufacture of an optical device which may be performed by the components described herein. However, themethod 1200 may be performed by other suitable components. - At a
block 1202, thelaser device 100 is burned-in. As has already been explained, thelaser device 100 comprises: alaser 103 attached to acarrier 101, a visible region (e.g. the protruding region 133) of thelaser 103 that includes anoutput facet 131 and at least a portion of awaveguide 129 configured to convey light out of thelaser 103, the visible region being visible to an imaging system (e.g. the imaging system 712) external to thelaser device 100. The burning-in may occur via thepower supply 601 and may be performed by placing thelaser device 100 in a burn-in rig, and the like, that includes connections to thepower supply 601 that connect to the electrical contacts 117; the burning-in may comprise monitoring the laser 103 (e.g. light emitted therefrom) and/or the burning-in may comprise operating thelaser 103 via thepower supply 601 according to a predetermined protocol to test for failure and/or life, and the like. - At a
block 1204, thelaser device 100 is positioned at asurface 702 of thePIC 700, using animaging system 712 and/or arobotic device 710 such that respectiveoptical axes 401, 751 (e.g. of theoutput facet 131 and aninput facet 731 of awaveguide 729 of the PIC 700), are about aligned. In specific examples, thelaser device 100 may be positioned at asurface 702 of thePIC 700 such that thecarrier 101 is located at thesurface 702 and thelaser 103 is located in acavity 701 of thePIC 700, as described above, such that such that respectiveoptical axes - At an
optional block 1206, thelaser device 100 may be further positioned to more precisely align the respectiveoptical axes 401, 751 (e.g. of theoutput facet 131 and the input facet 731) using thefeedback system 760, as well as using theimaging system 712 and/or therobotic device 710. - At a
block 1208, thecarrier 101 is attached to thesurface 702 of thePIC 700. For example, thecarrier 101 may be attached to thesurface 702 of thePIC 700 using the adhesive 1002, a polymer adhesive, a UV adhesive, a thermoset adhesive, and the like. When a UV adhesive is used, theblock 1208 may include curing the UV adhesive using UV light. Similarly, when a thermoset adhesive is used, theblock 1208 may include curing the thermoset adhesive using heat. In some examples, theblock 1208 may include attachingcarrier 101 to thesurface 702 of thePIC 700 using solder. - In general, the
method 1200 may be performed in an automated manner. - In particular, when the
block 1206 is implemented, prior to attaching thecarrier 101 to thesurface 702 of thePIC 700, at theblock 1208, themethod 1200 may further comprise: more precisely align the respectiveoptical axes output facet 131 and theinput facet 731 using thefeedback system 760 configured to assist with determining when theoutput facet 131 and theinput facet 731 are aligned; and in response to determining, using thefeedback system 760, that theoutput facet 131 and theinput facet 731 are more precisely aligned, attaching (e.g. at the block 1208) thecarrier 101 to thesurface 702 of thePIC 700 using thepolymer adhesive 1002. For example, thefeedback system 760 may determine that theoutput facet 131 and theinput facet 731 are more precisely aligned when thewaveguides imaging system 712. - As previously described, the
feedback system 760 may include theimaging system 712, and/or thefeedback system 760 may be in communication with theimaging system 712. Furthermore, as also previously described, theimaging system 712 may comprise a machine vision system positioned to image one or more of the visible region (e.g. the protruding region 133) and the alignment features 135 on the visible region (e.g. the protruding region 133), relative to thewaveguide 729 of thePIC 700. In some examples, themethod 1200 may further comprise imaging, using the machine vision system, one or more of the visible region (e.g. the protruding region 133) and the alignment features 135 relative to thewaveguide 729 of thePIC 700, during the moving of the laser device 103 (e.g. at the block 1206) to determine when theoutput facet 131 and theinput facet 731 are more precisely aligned. For example, thefeedback system 760 and/or theimaging system 712 may be configured to determine that when the alignment features 135 and/or thewaveguide 129 are located a given position relative to thewaveguide 729, thefacets - In some examples, the
method 1200 may further comprise operating thelaser device 100, during the moving of the laser device 100 (e.g. at theblock 1204 and/or the block 1206) to assist the machine vision system and/or theimaging system 712 with imaging one or more of the visible region (e.g. the protruding region 133) and the alignment features 135 relative to thewaveguide 729 of the PIC. In particular, operating thelaser device 100, during the moving of thelaser device 100 may assist the machine vision system and/or theimaging system 712 with determining when the light 603 exiting theoutput facet 131 is entering the input facet 731 (e.g. due to a reduction in light scattering and the like, and or via thewaveguide 729 emitting a portion of the light 603 travelling through the waveguide 729). - As has already been described, in some examples, the visible region (e.g. the protruding region 133) includes the alignment features 135. In some of these examples, the
method 1200 may further comprise: imaging, using theimaging system 712, the alignment features 135 to assist with one or more of: positioning (e.g. at the block 1204), using theimaging system 712 and/or therobotic device 710, thelaser device 100 at the surface of thePIC 700; and moving (e.g. at the block 1206), using theimaging system 712 and/or therobotic device 710, thelaser device 100 to more precisely align theoutput facet 131 with theinput facet 731. Again, thefeedback system 760 and/or theimaging system 712 may be configured to determine that when the alignment features 135 and/orwaveguide 129 are located a given position relative to thewaveguide 729, thefacets - As has already been described, in some examples, the
feedback system 760 may comprise one or more of a power measurement device and a light measurement device in optical communication with theinput facet 731 via thewaveguide 729; in these examples, themethod 1200 may further comprise determining, using thefeedback system 760, that the respectiveoptical axes - In other examples, however, the
block 1206 may be omitted and themethod 1200 may further comprise using apolymer waveguide 1101 to optically connect theoutput facet 131 to theinput facet 731. In such examples, any suitable device and/or material may be used to form thepolymer waveguide 1101. - In some examples, polymer waveguides (and/or 3D-printed polymer waveguides) may be used in combination with attaching laser devices to a PIC in other configurations that may not include a cavity. For example, attention is next directed to
FIG. 13 which schematically depicts a laser device 1300 (and/or alaser assembly 1300, and the like) comprising acarrier 1301 and alaser 1303 attached thereto; however, in contrast to thecarrier 101 and thelaser 103, thelaser 1303 is attached to thecarrier 1301 with alasing device 1323, as well as awaveguide 1329 and a respective output facet 1331 (e.g. an output portion), at a side opposite thecarrier 1301. However, in other examples, thelaser device 1300 may be similar to, and/or the same as, thelaser device 100. While details of thecarrier 1301 and thelaser 1303 are not depicted, it is understood that thelaser 1303 includes a lasing device similar to thelasing device 123, and the like. - As also depicted in
FIG. 13 , thedevice 1300 is attached to a surface of aPIC 1340, for example using an adhesive, and the like, at a side of thecarrier 1301 opposite that of thelaser 1303. In contrast to thedevice 100 and thePIC 700, thelaser 1303 is not located in a cavity of thePIC 1340; indeed, as depicted, thePIC 1340 does not include a cavity similar to thecavity 701. - Furthermore, the side of the
laser 1303 that includes thewaveguide 1329 and arespective output facet 1331 may comprise a visible region, which may be used to position and/or align thedevice 1300 at thePIC 1340, as described above with respect to themethod 1200. The visible region may include alignment features, similar to the alignment features 135, as described above. - In particular, the
laser 1303 may be burned-in prior to attachment to thePIC 1340 as described above. As depicted, thePIC 1340 comprises awaveguide 1339 and a corresponding input facet 1341 (e.g. an input portion), which may be respectively similar to thewaveguide 729 and theinput facet 731, however thewaveguide 1339 and theinput facet 1341 are not located at a cavity. - As depicted, the
facets facets facets facets output facet 1331 is conveyed to theinput facet 1341 via thepolymer waveguide 1351. However, any suitable optical coupling device may be used to couple thefacets - In some examples, during attachment of the
device 1300 to thePIC 1340, thedevice 1300 may be located at thePIC 1340 to minimize and/or reduce a distance between thefacets polymer waveguide 1351. - Hence, in these examples, the
device 1300 may be fabricated and/or burned-in (and/or screened by testing and/or tested) prior to attachment to thePIC 1340, attached to thePIC 1340 and thepolymer waveguide 1351 may be attached between thefacets facets device 1300 may include alignment features (e.g. similar to the alignment features 135 and adjacent thewaveguide 1329 at a surface visible to an imaging system) to assist withpositioning device 1300 at thePIC 1340. Furthermore, while not depicted, it is further understood that electrical connections to theassembly 1300 can be made to the electrical contacts (e.g. similar to the electrical contacts 117) using one or more of bonded wire, conductive adhesive, contact pins, solder, and the like, for example to electrically connect theassembly 700 to thePIC 1340 and/or another device which operates thelaser 1323 during operation of an optical device into which theassembly 1300 and thePIC 1340 are incorporated. - In this specification, elements may be described as “configured to” perform one or more functions or “configured for” such functions. In general, an element that is configured to perform or configured for performing a function is enabled to perform the function, or is suitable for performing the function, or is adapted to perform the function, or is operable to perform the function, or is otherwise capable of performing the function.
- It is understood that for the purpose of this specification, language of “at least one of X, Y, and Z” and “one or more of X, Y and Z” can be construed as X only, Y only, Z only, or any combination of two or more items X, Y, and Z (e.g., XYZ, XY, YZ, XZ, and the like). Similar logic can be applied for two or more items in any occurrence of “at least one . . . ” and “one or more . . . ” language.
- The terms “about”, “substantially”, “essentially”, “approximately”, and the like, are defined as being “close to”, for example as understood by persons of skill in the art. In some examples, the terms are understood to be “within 10%,” in other examples, “within 5%”, in yet further examples, “within 1%”, and in yet further examples “within 0.5%”.
- Persons skilled in the art will appreciate that in some examples, the functionality of devices and/or methods and/or processes described herein can be implemented using pre-programmed hardware or firmware elements (e.g., application specific integrated circuits (ASICs), electrically erasable programmable read-only memories (EEPROMs), etc.), or other related components. In other examples, the functionality of the devices and/or methods and/or processes described herein can be achieved using a computing apparatus that has access to a code memory (not shown) which stores computer-readable program code for operation of the computing apparatus. The computer-readable program code could be stored on a computer readable storage medium which is fixed, tangible and readable directly by these components, (e.g., removable diskette, CD-ROM, ROM, fixed disk, USB drive). Furthermore, it is appreciated that the computer-readable program can be stored as a computer program product comprising a computer usable medium. Further, a persistent storage device can comprise the computer readable program code. It is yet further appreciated that the computer-readable program code and/or computer usable medium can comprise a non-transitory computer-readable program code and/or non-transitory computer usable medium. Alternatively, the computer-readable program code could be stored remotely but transmittable to these components via a modem or other interface device connected to a network (including, without limitation, the Internet) over a transmission medium. The transmission medium can be either a non-mobile medium (e.g., optical and/or digital and/or analog communications lines) or a mobile medium (e.g., microwave, infrared, free-space optical or other transmission schemes) or a combination thereof.
- Persons skilled in the art will appreciate that there are yet more alternative examples and modifications possible, and that the above examples are only illustrations of one or more embodiments. The scope, therefore, is only to be limited by the claims appended hereto.
Claims (18)
1. A device comprising:
a carrier comprising:
a first side, a second side opposing the first side, and an edge joining the first side and the second side; through-carrier vias (TCVs) from the first side to the second side, the TCVs including electrical connections therethrough; first electrical contacts for the electrical connections at the first side; and second electrical contacts for the electrical connections at the second side; and
a laser attached to the second side of the carrier, the laser comprising:
a body supporting components of the laser; a lasing device configured to produce light, the lasing device located at a respective side of the body attached to the second side of the carrier;
respective electrical connections from the second electrical contacts to the lasing device; and
a protruding region of the body protruding the edge of the carrier, the body otherwise having a smaller footprint than the carrier; and
an output portion configured to convey light from the lasing device out of the laser, the output portion located at the protruding region of the body.
2. The device of claim 1 , further comprising, at mating surfaces of one or more of the second side of the carrier and the body, one or more of pedestals and recesses configured to locate the output portion and a waveguide optical axis at a given plane, parallel to the second side.
3. The device of claim 1 , wherein the body of the laser is configured to reside in a photonic integrated circuit (PIC) cavity, supported by the carrier.
4. The device of claim 1 , further comprising, at the protruding region, alignment features configured to facilitate one or more of machine and human vision alignment of the output portion, and a corresponding waveguide of the laser which ends at the output portion, with an input portion, and respective waveguide, of a PIC.
5. The device of claim 1 , wherein the carrier further comprises a recess at the second side, the second electrical contacts located at least partially in the recess at the second side.
6. A device comprising:
a photonic integrated circuit (PIC) including a waveguide, an input portion to the waveguide; and a cavity, the input portion located at an interior edge of the of the cavity; and
a laser device comprising:
a carrier comprising: opposing sides joined by an edge; through-carrier-vias (TCVs) between the opposing sides, the TCVs including electrical connections therethrough; and
a laser attached to a given side of the opposing sides of the carrier, the laser comprising: a body supporting components of the laser; a lasing device configured to produce light for the PIC, the lasing device located between the given side of the carrier and the body; respective electrical connections from the lasing device to the electrical connections of the TCVs; and an output portion and respective waveguide configured to convey the light from the lasing device out of the laser, a protruding region of the body, supporting the output portion, and the respective waveguide, protruding the edge of the carrier, the body otherwise having a smaller footprint than the carrier,
the body located in the cavity of the PIC with the output portion and the respective waveguide respectively aligned with the input portion and the waveguide of the PIC, the carrier attached to the PIC, the carrier supporting the body in the cavity.
7. The device of claim 6 , wherein a first plane of the PIC, that includes a waveguide optical axis of the waveguide and is about parallel to mating surfaces of the carrier and the laser device, is aligned with a second plane of the body, that includes a respective waveguide optical axis of the respective waveguide and is about parallel to the mating surfaces of the carrier and the laser device.
8. The device of claim 6 , wherein a first plane of the PIC includes a waveguide optical axis of the waveguide, and is about parallel to mating surfaces of the carrier and the laser device, and the device further comprises, at one or more of the given side of the carrier and a respective side of the body attached to the given side, one or more of pedestals and recesses configured to locate the waveguide optical axis at a second plane that aligns with the first plane when the carrier is attached to the PIC, the second plane being about perpendicular to the output portion.
9. The device of claim 8 , wherein the one or more of the pedestals and the recesses locate the output portion and the waveguide optical axis at the second plane relative to a surface of the carrier that is attached to the PIC.
10. A method comprising:
burning-in a laser device, the laser device comprising: a laser attached to a carrier, a visible region of the laser, that includes an output portion and at least a portion of a waveguide configured to convey light out of the laser, the visible region being visible to an imaging system external to the laser device;
positioning, using one or more of the imaging system and a robotic device, the laser device at a surface of a photonic integrated circuit (PIC) such that respective optical axes of the output portion and an input portion of a waveguide of the PIC, are about aligned; and
attaching the carrier to the surface of the PIC.
11. The method of claim 10 , further comprising:
prior to attaching the carrier to the surface of the PIC: moving, using one or more of the imaging system and the robotic device, the laser device to more precisely align the respective optical axes of the output portion and the input portion using a feedback system configured to assist with determining when the output portion and the input portion are aligned; and
in response to determining, using the feedback system, that the output portion and the input portion are more precisely aligned, attaching the carrier to the surface of the PIC.
12. The method of claim 11 , wherein the feedback system comprises a machine vision system positioned to image one or more of the visible region and alignment features on the visible region, relative to the waveguide of the PIC and the method further comprises:
imaging, using the machine vision system, one or more of the visible region and the alignment features relative to the waveguide of the PIC, during the moving of the laser device to determine when the output portion and the input portion are more precisely aligned.
13. The method of claim 12 , further comprising operating the laser device, during the moving of the laser device to assist the machine vision system with imaging one or more of the visible region and the alignment features relative to the waveguide of the PIC.
14. The method of claim 11 , wherein the visible region includes alignment features, and the method further comprises:
imaging, using a machine vision system, the alignment features to assist with one or more of: locating, using the imaging system, the laser device at the surface of the PIC; and moving, using the robotic device, the laser device to more precisely align the output portion with the input portion.
15. The method of claim 11 , wherein the feedback system comprises one or more of a power measurement device and a light measurement device in optical communication with the input portion via the waveguide, wherein the determining, using the feedback system, that the respective optical axes of the output portion and the input portion are more precisely aligned comprises: determining that an output signal of one or more of the power measurement device and the light measurement device is about maximized at a given location of the laser device relative to the PIC.
16. The method of claim 10 , further comprising:
using a polymer waveguide to optically connect the output portion to the input portion.
17. The method of claim 10 , wherein attaching the carrier to the surface of the PIC occurs using one or more of a polymer adhesive, a thermoset adhesive and an ultra-violet (UV) adhesive.
18. A device comprising:
a photonic integrated circuit (PIC) including a waveguide and an input portion to the waveguide; and
a laser device attached to the PIC, the laser device comprising: a carrier; a laser attached to the carrier, the laser comprising: a lasing device, a respective waveguide, an output portion, and a visible region of the laser that includes the output portion and at least a portion of the waveguide configured to convey light out of the laser via the output portion to the input portion of the PIC, the output portion and the input portion being optically coupled via an optical coupling device, the visible region being visible to an imaging system external to the laser device.
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US18/222,546 US20230367061A1 (en) | 2020-05-22 | 2023-07-17 | Carrier based laser assembly and method of assembly thereof with photonic integrated circuit |
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US10931080B2 (en) * | 2018-09-17 | 2021-02-23 | Waymo Llc | Laser package with high precision lens |
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