US6259841B1 — Reflective coupling array for optical waveguide

Claim 1

Independent Claim 97 words

An optical device for routing a plurality of different wavelengths comprising: a waveguide for propagating the different wavelengths within a plane; a wavelength separator that directs the different wavelengths through separate foci along a focal line that lies within said plane; a plurality of reflective surface portions that fold the wavelengths out of said plane and into alignment with an array of input/outputs; and at least some of said reflective surface portions being offset from said focal line within said plane so that said input/outputs can be spaced closer together in a dimension along the focal line.

Claim 2

Dependent Claim 97 words

An optical device for routing a plurality of different wavelengths comprising: a waveguide for propagating the different wavelengths within a plane; a wavelength separator that directs the different wavelengths through separate foci along a focal line that lies within said plane; a plurality of reflective surface portions that fold the wavelengths out of said plane and into alignment with an array of input/outputs; and at least some of said reflective surface portions being offset from said focal line within said plane so that said input/outputs can be spaced closer together in a dimension along the focal line.

Claim 3

Dependent Claim 24 words

The device of claim 1 in which said reflective surface portions are located along a centerline that intersects said focal line at an angle.

Claim 4

Dependent Claim 29 words

The device of claim 2 in which the input/outputs are positioned closer together by a factor of the cosine of the angle between the centerline and the focal line.

Claim 5

Dependent Claim 31 words

The device of claim 2 in which said reflective surface portions are inclined collectively to said plane through a common angle and are inclined individually to said centerline by varying angles.

Claim 6

Dependent Claim 28 words

The device of claim 1 in which said reflective surface portions are curved to refocus the different wavelengths for better matching desired mode field dimensions of the input/outputs.

Claim 7

Dependent Claim 22 words

The device of claim 1 in which said waveguide is a planar waveguide having a core layer surrounded by layers of cladding.

Claim 8

Dependent Claim 26 words

The device of claim 6 in which at least one cavity is formed through said core layer of the waveguide for mounting said reflective surface portions.

Claim 9

Dependent Claim 24 words

The device of claim 7 in which said cavity includes first and second surfaces facing the direction of wavelength propagation through the planar waveguide.

Claim 10

Dependent Claim 23 words

The device of claim 8 in which said first and second surfaces are oriented through a common angle with respect to said plane.

Claim 11

Dependent Claim 30 words

The device of claim 9 in which said first surface is a boundary surface, and the wavelengths are folded out of the plane by internal reflection from said first surface.

Claim 12

Dependent Claim 22 words

The device of claim 9 in which said second surface includes a reflective coating for folding the wavelengths out of the plane.

Claim 13

Dependent Claim 23 words

The device of claim 11 in which said cavity is filled with an index-matching material for preventing internal reflections from said first surface.

Claim 14

Dependent Claim 35 words

The device of claim 7 in which said reflective surface portions are formed by an continuous fiber mounted in said cavity and having a flat side surface for reflecting the wavelengths out of the plane.

Claim 15

Dependent Claim 15 words

The device of claim 13 in which said continuous fiber has a triangular cross section.

Claim 16

Dependent Claim 32 words

The device of claim 7 in which said cavity contains a reflective grating that functions as at least one of said reflective surface portions for folding the wavelengths out of the plane.

Claim 17

Dependent Claim 31 words

The device of claim 15 in which said reflective grating is a volume grating having a plurality of layers that vary in refractive index for producing a series of partial reflections.

Claim 18

Dependent Claim 18 words

The device of claim 16 in which said layers are oriented at a common angle to said plane.

Claim 19

Dependent Claim 22 words

The device of claim 15 in which said reflective grating also functions as a filter for reflecting a limited band of wavelengths.

Claim 20

Dependent Claim 30 words

The device of claim 7 in which said cavity is filled with a first material that is fashioned into a slope and covered with a second material for enhancing reflectivity.

Claim 21

Dependent Claim 23 words

The device of claim 19 in which said first material is different from materials used to form said layers of core and cladding.

Claim 22

Dependent Claim 20 words

The device of claim 20 in which said first material is an organic material susceptible to photoablation by ultraviolet irradiation.

Claim 23

Dependent Claim 20 words

The device of claim 20 in which said first material is a photosensitive material that is selectively removable by development.

Claim 24

Dependent Claim 22 words

The device of claim 1 in which said input/outputs are optical fibers having inner ends aligned with said plurality of reflective surfaces.

Claim 25

Dependent Claim 28 words

The device of claim 23 in which said inner ends of the optical fibers incorporate focusing optics for improving coupling efficiency between said fibers and said reflective surfaces.

Claim 26

Dependent Claim 14 words

The device of claim 24 in which said focusing optics are fiber GRIN lenses.

Claim 27

Dependent Claim 12 words

The device of claim 24 in which said focusing optics are microlenses.

Claim 28

Dependent Claim 102 words

An optical device having an optical axis with respect to which a plurality of wavelengths are separated comprising: a wavelength separator that spatially distinguishes the different wavelengths from the optical axis in a plane of propagation; an array of input/outputs extending out of said plane of propagation; a reflector array that folds the different wavelengths into alignment with said array of input/outputs; and said reflector array including individual reflectors that are offset from a line perpendicular to the optical axis within said plane of propagation so that said input/outputs can be spaced closer together in a dimension perpendicular to the optical axis.

Claim 29

Dependent Claim 102 words

An optical device having an optical axis with respect to which a plurality of wavelengths are separated comprising: a wavelength separator that spatially distinguishes the different wavelengths from the optical axis in a plane of propagation; an array of input/outputs extending out of said plane of propagation; a reflector array that folds the different wavelengths into alignment with said array of input/outputs; and said reflector array including individual reflectors that are offset from a line perpendicular to the optical axis within said plane of propagation so that said input/outputs can be spaced closer together in a dimension perpendicular to the optical axis.

Claim 30

Dependent Claim 12 words

The device of claim 27 in which said input/outputs are optical fibers.

Claim 31

Dependent Claim 19 words

The device of claim 28 in which said reflector array is formed by inclined ends of said optical fibers.

Claim 32

Dependent Claim 31 words

The device of claim 29 in which said inclined ends have a reflective surface for folding the different wavelengths between said plane of propagation and another plane containing said optical fibers.

Claim 33

Dependent Claim 17 words

The device of claim 30 in which said inclined ends are mounted in a common optical support.

Claim 34

Dependent Claim 34 words

The device of claim 27 in which said input/outputs are arranged along a single straight line that is inclined in said plane of propagation to said line that is perpendicular to the optical axis.

Claim 35

Dependent Claim 17 words

The device of claim 32 in which said input/output array is mounted in a common optical support.

Claim 36

Dependent Claim 18 words

The device of claim 33 including a planar waveguide for guiding the wavelengths along said plane of propagation.

Claim 37

Dependent Claim 30 words

The device of claim 34 in which said planar waveguide includes top and bottom surfaces, and said common optical support is attached to said top surface of the planar waveguide.

Claim 38

Dependent Claim 23 words

The device of claim 27 in which said reflector array is arranged for conveying wavelengths throughout a continuous spectrum to said input/output array.

Claim 39

Dependent Claim 27 words

The device of claim 36 in which said input/outputs are positioned close enough together in the dimension perpendicular to the optical axis for conveying the continuous spectrum.

Claim 40

Dependent Claim 14 words

The device of claim 37 in which said optical device is a dispersion compensator.

Claim 41

Dependent Claim 24 words

The device of claim 27 in which said individual reflectors of the reflector array are formed by different portions of a continuous reflective surface.

Claim 42

Dependent Claim 24 words

The device of claim 39 in which said continuous reflective surface is formed by an optical fiber having a flat surface for reflecting light.

Claim 43

Dependent Claim 18 words

The device of claim 27 in which said reflector array is formed by at least one reflective grating.

Claim 44

Dependent Claim 24 words

The device of claim 41 in which said reflective grating is a volume grating composed of alternating layers of materials having differing refractive indices.

Claim 45

Dependent Claim 39 words

The device of claim 27 in which said reflector array is formed in a waveguide by at least one boundary surface that provides total internal reflection of the wavelengths between said plane of propagation and said array of input/outputs.

Claim 46

Dependent Claim 23 words

The device of claim 43 in which said boundary surface is formed by an undercut surface of a cavity formed in the waveguide.

Claim 47

Dependent Claim 36 words

The device of claim 27 in which said reflector array is formed in at least one cavity of a waveguide having opposing surfaces commonly inclined at an approximately 45 degree angle to said plane of propagation.

Claim 48

Dependent Claim 31 words

The device of claim 45 in which one of said opposing surfaces is covered with a reflective material, and a remaining portion of said cavity is filled with an index-matching material.

Claim 49

Dependent Claim 38 words

The device of claim 27 in which said reflector array is formed in at least one cavity of a waveguide, and said cavity is partially filled with a material that is different from that of the surrounding waveguide.

Claim 50

Dependent Claim 19 words

The device of claim 47 in which said material is an organic material susceptible to photoablation by ultraviolet irradiation.

Claim 51

Dependent Claim 19 words

The device of claim 47 in which said material is a photosensitive material that is selectively removable by development.

Claim 52

Independent Claim 166 words

A method of making an optical coupling in a planar waveguide having a mechanism for spatially distinguishing different wavelengths along a focal line comprising the steps of: relatively orienting the planar waveguide with respect to a directed beam so that the directed beam is inclined at a non-normal angle of incidence to a surface of the planar waveguide; removing a volume of material from the planar waveguide exposing a core layer of the planar waveguide; forming inclined surface portions through the core layer of the planar waveguide in alignment with the directed beam; mounting an array of input/outputs on the surface of the planar waveguide so that wavelengths propagating in the core layer of the planar waveguide and reflected by the inclined surface portions are coupled to the input/outputs of the array; and orienting at least some of said reflective surface portions offset from said focal line within said plane so that said input/outputs can be spaced closer together in a dimension along the focal line.

Claim 53

Independent Claim 166 words

A method of making an optical coupling in a planar waveguide having a mechanism for spatially distinguishing different wavelengths along a focal line comprising the steps of: relatively orienting the planar waveguide with respect to a directed beam so that the directed beam is inclined at a non-normal angle of incidence to a surface of the planar waveguide; removing a volume of material from the planar waveguide exposing a core layer of the planar waveguide; forming inclined surface portions through the core layer of the planar waveguide in alignment with the directed beam; mounting an array of input/outputs on the surface of the planar waveguide so that wavelengths propagating in the core layer of the planar waveguide and reflected by the inclined surface portions are coupled to the input/outputs of the array; and orienting at least some of said reflective surface portions offset from said focal line within said plane so that said input/outputs can be spaced closer together in a dimension along the focal line.

Claim 54

Dependent Claim 29 words

The method of claim 50 in which said step of removing includes etching a plurality of cavities having opposing side walls commonly inclined at the non-normal angle of incidence.

Claim 55

Dependent Claim 27 words

The method of claim 51 in which the inclined surface portions are formed by one of the opposing side walls inclined at the non-normal angle of incidence.

Claim 56

Dependent Claim 35 words

The method of claim 52 including the further step of applying a mask to the surface of the planar waveguide, leaving openings for exposing a plurality of areas on the surface of the planar waveguide.

Claim 57

Dependent Claim 30 words

The method of claim 53 in which said step of removing includes directing a beam of plasma at the non-normal angle of incidence to the surface of the planar waveguide.

Claim 58

Dependent Claim 26 words

The method of claim 52 in which one of the opposing side walls undercuts the surface of the planar waveguide and forms the inclined surface portions.

Claim 59

Dependent Claim 54 words

The method of claim 52 including the further steps of: applying a reflective coating on one of the opposing side walls for forming the inclined surface portions, and filling the cavities with a material matched in refractive index to the core layer for avoiding internal reflections from the other of the opposing side walls.

Claim 60

Dependent Claim 27 words

The method of claim 50 in which said step of removing includes etching a plurality of cavities prior to said step of relatively orienting the planar waveguide.

Claim 61

Dependent Claim 17 words

The method of claim 57 including the further step of filling the cavities with an organic material.

Claim 62

Dependent Claim 36 words

The method of claim 58 in which the directed beam is composed of ultraviolet light, and said step of forming inclined surface portions includes using the directed beam to remove a portion of the organic material.

Claim 63

Dependent Claim 17 words

The method of claim 57 including the further step of filling the cavities with a photosensitive material.

Claim 64

Dependent Claim 33 words

The method of claim 60 in which said step of forming inclined surface portions includes using the directed beam to develop a portion of the photosensitive material and subsequently removing the developed portion.

Claim 65

Independent Claim 120 words

A method of forming an out-of-plane mirror within a planar waveguide comprising the steps of: applying a mask to a surface of the planar waveguide, leaving openings for exposing a plurality of areas on the surface of the planar waveguide; relatively orienting the planar waveguide with respect to a directed beam of plasma so that the directed beam is inclined at a non-normal angle of incidence to the exposed surface of the planar waveguide; using the directed beam to etch a cavity in the planar waveguide having opposing side walls commonly inclined at the non-normal angle of incidence; and orienting at least one of said opposing side walls to support total internal reflection of light propagating in the planar waveguide.

Claim 66

Independent Claim 120 words

A method of forming an out-of-plane mirror within a planar waveguide comprising the steps of: applying a mask to a surface of the planar waveguide, leaving openings for exposing a plurality of areas on the surface of the planar waveguide; relatively orienting the planar waveguide with respect to a directed beam of plasma so that the directed beam is inclined at a non-normal angle of incidence to the exposed surface of the planar waveguide; using the directed beam to etch a cavity in the planar waveguide having opposing side walls commonly inclined at the non-normal angle of incidence; and orienting at least one of said opposing side walls to support total internal reflection of light propagating in the planar waveguide.

Claim 67

Dependent Claim 17 words

The method of claim 62 in which one of said opposing side walls forms the out-of-plane mirror.

Claim 68

Dependent Claim 25 words

The method of claim 63 in which one of the opposing side walls undercuts the surface of the planar waveguide and forms the out-of-plane mirror.

Claim 69

Dependent Claim 26 words

The method of claim 63 including the further step of applying a reflective coating on one of the opposing side walls for forming the out-of-plane mirror.

Claim 70

Dependent Claim 40 words

The method of claim 65 including the further step of filling the cavity with a material matched in refractive index to a core layer of the planar waveguide for avoiding internal reflections from the other of the opposing side walls.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	2004-07-09	2005-01-08	2005-07-10	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2008-07-09	2009-01-08	2009-07-10	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2012-07-09	2013-01-08	2013-07-10	$7700.00	Window Closed / Lapsed

Reflective coupling array for optical waveguide

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