阅读说明：本技术 端面耦合器及其制造方法 (End-face coupler and manufacturing method thereof ) 是由 李博文 冯俊波 朱继光 曹国威 于 2020-12-22 设计创作，主要内容包括：本公开提供一种端面耦合器及其制造方法。该方法包括：提供绝缘体上半导体衬底,所述绝缘体上半导体衬底包括第一衬底、第一衬底上的绝缘层以及绝缘层上的半导体层；对半导体层进行图案化以形成第一波导；在绝缘层上形成第一介质层；在第一介质层和第一波导上形成第二介质层；在第二介质层上形成第二波导；形成覆盖第二波导的第三介质层；在第三介质层远离第二波导的一侧,将第三介质层键合至载体衬底；去除第一衬底；以及在绝缘层的表面上形成第四介质层。(The present disclosure provides an end-face coupler and a method of manufacturing the same. The method comprises the following steps: providing a semiconductor-on-insulator substrate comprising a first substrate, an insulating layer on the first substrate, and a semiconductor layer on the insulating layer; patterning the semiconductor layer to form a first waveguide; forming a first dielectric layer on the insulating layer; forming a second dielectric layer on the first dielectric layer and the first waveguide; forming a second waveguide on the second dielectric layer; forming a third dielectric layer covering the second waveguide; bonding the third dielectric layer to the carrier substrate at a side of the third dielectric layer remote from the second waveguide; removing the first substrate; and forming a fourth dielectric layer on the surface of the insulating layer.)

1. A method of manufacturing an end-face coupler, comprising:

providing a semiconductor-on-insulator substrate comprising a first substrate, an insulating layer on the first substrate, and a semiconductor layer on the insulating layer;

patterning the semiconductor layer to form a first waveguide;

forming a first dielectric layer on the insulating layer;

forming a second dielectric layer on the first dielectric layer and the first waveguide;

forming a second waveguide on the second dielectric layer;

forming a third dielectric layer covering the second waveguide;

bonding the third dielectric layer to a carrier substrate on a side of the third dielectric layer remote from the second waveguide;

removing the first substrate; and

and forming a fourth dielectric layer on the surface of the insulating layer.

2. The method of claim 1, further comprising: forming a barrier layer on the semiconductor layer prior to patterning the semiconductor layer,

wherein patterning the semiconductor layer to form a first waveguide comprises:

patterning the barrier layer and the semiconductor layer to form the first waveguide.

3. The method of claim 2, wherein forming a first dielectric layer on the insulating layer comprises:

forming a first dielectric material layer covering the barrier layer and the insulating layer; and

planarizing the first dielectric material layer until the barrier layer is completely removed to form the first dielectric layer,

wherein a surface of the first dielectric layer distal from the first substrate is substantially flush with a surface of the first waveguide distal from the first substrate.

4. The method of claim 1, wherein forming a second waveguide on the second dielectric layer comprises:

forming a second waveguide material layer on the second dielectric layer; and

patterning the second waveguide material layer to form the second waveguide.

5. An end-face coupler comprising:

a first waveguide;

a first dielectric layer adjacent to the first waveguide;

a second dielectric layer on the first waveguide and the first dielectric layer;

a second waveguide on the second dielectric layer;

a third dielectric layer covering the second waveguide;

a carrier substrate on the third dielectric layer;

an insulating layer located below the first waveguide and the first dielectric layer; and

and the fourth dielectric layer is positioned below the insulating layer.

6. The end-face coupler of claim 5 wherein the second waveguide comprises a transition waveguide and a transmission waveguide, wherein,

the conversion waveguide is used for performing mode spot conversion on light received from the optical fiber and transmitting the mode spot converted light to the transmission waveguide; and

at least a portion of the transmission waveguide is vertically aligned with at least a portion of the first waveguide to couple light transmitted in the transmission waveguide into the first waveguide.

7. The end-face coupler of claim 6,

at least a portion of the transition waveguide tapers in size in a direction perpendicular to a direction of proximity to the optical fiber.

8. The end-face coupler of claim 7 wherein the conversion waveguide is a linear tapered waveguide, a non-linear tapered waveguide, or a sub-wavelength grating.

9. The end-face coupler of claim 8 wherein the conversion waveguide is a sub-wavelength grating, and

wherein the sub-wavelength grating includes a first grating portion and a second grating portion,

wherein the first grating portion includes a plurality of first grating structure units arranged at a first grating period, the plurality of first grating structure units being gradually reduced in size in a direction approaching the optical fiber and in a direction perpendicular to the direction approaching the optical fiber, and

wherein the second grating portion includes a plurality of second grating structure units arranged at a second grating period and a tapered unit connected to the plurality of second grating structure units, the plurality of second grating structure units are the same in size, and the tapered unit is tapered in a direction approaching the optical fiber.

10. The end-face coupler of claim 9,

the geometric size of a first grating structure unit of the plurality of first grating structure units, which is closest to the optical fiber, is determined based on a spot diameter of the optical fiber.

Technical Field

The present disclosure relates to the field of semiconductor technologies, and in particular, to an end-face coupler and a method for manufacturing the same.

Background

The silicon optical integration technology is widely applied to important fields of large-capacity communication, optical signal processing, avionics systems and the like. At present, one of the key problems inhibiting the widespread use of silicon photonic chips is the coupling of optical fibers to the silicon photonic chips.

In some cases, the spot size of the optical waveguide in a silicon photonic chip differs significantly from the spot size of the optical fiber, resulting in high silicon photonic-fiber coupling loss due to spot mismatch. Thus, the coupling problem between the optical fiber and the optical waveguide in the chip can generally be realized by a coupler.

The coupler in the related art has problems of low coupling efficiency and the like. In order to improve the coupling efficiency, the key parts of some couplers are in a suspended state, which results in low reliability of the structure, and the coupler is easy to break in the processes of wafer scribing and chip packaging, thereby increasing the cost and inhibiting the yield. In addition, some couplers have a complex structure, and require precise control of the growth of multiple layers of materials and the distance between the layers, resulting in high process requirements and increased cost.

Disclosure of Invention

It would be advantageous to provide a mechanism that alleviates, mitigates or even eliminates one or more of the above-mentioned problems.

According to some embodiments of the present disclosure, there is provided a method of manufacturing an end-face coupler, including: providing a semiconductor-on-insulator substrate comprising a first substrate, an insulating layer on the first substrate, and a semiconductor layer on the insulating layer; patterning the semiconductor layer to form a first waveguide; forming a first dielectric layer on the insulating layer; forming a second dielectric layer on the first dielectric layer and the first waveguide; forming a second waveguide on the second dielectric layer; forming a third dielectric layer covering the second waveguide; bonding the third dielectric layer to the carrier substrate at a side of the third dielectric layer remote from the second waveguide; removing the first substrate; and forming a fourth dielectric layer on the surface of the insulating layer.

There is also provided, in accordance with some embodiments of the present disclosure, an end-face coupler, including: a first waveguide; a first dielectric layer adjacent to the first waveguide; a second dielectric layer on the first waveguide and the first dielectric layer; a second waveguide on the second dielectric layer; a third dielectric layer covering the second waveguide; a carrier substrate on the third dielectric layer; an insulating layer located below the first waveguide and the first dielectric layer; and a fourth dielectric layer located under the insulating layer.

These and other aspects of the disclosure will be apparent from and elucidated with reference to the embodiments described hereinafter.

Drawings

Further details, features and advantages of the disclosure are disclosed in the following description of exemplary embodiments, taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a flow chart of a method of manufacturing an end-face coupler according to an exemplary embodiment of the present disclosure;

fig. 2A to 2K are schematic cross-sectional views of exemplary structures of end-face couplers formed in respective steps of a method of manufacturing the end-face couplers according to an exemplary embodiment of the present disclosure;

fig. 3A to 3C are schematic structural diagrams of a second waveguide according to an exemplary embodiment of the present disclosure; and

fig. 4 is a schematic diagram of a partial structure of an end-face coupler according to an exemplary embodiment of the present disclosure.

Detailed Description

It will be understood that, although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the present disclosure.

Spatially relative terms such as "below …," "below …," "lower," "below …," "above …," "upper," and the like may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that these spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" or "under" other elements or features would then be oriented "above" the other elements or features. Thus, the exemplary terms "below …" and "below …" may encompass both an orientation above … and below …. Terms such as "before …" or "before …" and "after …" or "next to" may similarly be used, for example, to indicate the order in which light passes through the elements. The devices may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. In addition, it will also be understood that when a layer is referred to as being "between" two layers, it can be the only layer between the two layers, or one or more intervening layers may also be present.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items, and the phrase "at least one of a and B" refers to a alone, B alone, or both a and B.

It will be understood that when an element or layer is referred to as being "on," "connected to," "coupled to" or "adjacent to" another element or layer, it can be directly on, connected to, coupled to or adjacent to the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly connected to," "directly coupled to," or "directly adjacent to" another element or layer, there are no intervening elements or layers present. However, neither "on … nor" directly on … "should be construed as requiring that one layer completely cover an underlying layer in any event.

Embodiments of the present disclosure are described herein with reference to schematic illustrations (and intermediate structures) of idealized embodiments of the present disclosure. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, embodiments of the present disclosure should not be construed as limited to the particular shapes of regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing. Thus, the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the actual shape of a region of a device and are not intended to limit the scope of the present disclosure.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and/or the present specification and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

As used herein, the term "substrate" may refer to a substrate of a diced wafer, or may refer to a substrate of an unslit wafer. Similarly, the terms chip and die may be used interchangeably unless such interchange causes a conflict. It should be understood that the term "film" includes layers, which unless otherwise specified, should not be construed to indicate vertical or horizontal thickness. It should be noted that the thicknesses of the material layers of the hydrophone shown in the drawings are merely schematic and do not represent actual thicknesses.

Optical coupling may be achieved between the fiber and the chip by a coupler. In practical applications, the aforementioned optical coupling may be achieved by a surface coupler or an end-face coupler. For example, surface couplers use solutions based on diffraction gratings, which mainly use a grating structure to couple light into an optical waveguide in a diffractive form. However, the conventional grating coupler has a length of hundreds of micrometers, which makes the leakage factor of the grating very small, but limits the bandwidth of the grating coupler. In order to improve the defects of the surface coupler, the use of an end coupler is sometimes considered. However, the key portion of the conventional end-face coupler is often in a suspended state, and the core portion of the coupler needs to be supported by a beam, so that the structural reliability is not high, and the coupler is easy to break in the processes of wafer scribing and chip packaging, so that the cost is increased, and the yield is inhibited. In addition, some end-face couplers have a complicated structure, and require precise control over the growth of multiple layers of materials and the distance between the multiple layers of materials, which results in high process requirements and increased cost.

Embodiments of the present disclosure provide a method of manufacturing an end-face coupler and an end-face coupler. Manufacturing the end-face coupler by the method according to the embodiments of the present disclosure helps to improve coupling efficiency, improve reliability, reduce device size, and reduce process cost.

Fig. 1 is a flow chart of a method 100 of manufacturing an end-face coupler according to an exemplary embodiment of the present disclosure, and fig. 2A to 2K are schematic diagrams of example structures formed by various steps of the method 100. The method 100 is described below with reference to fig. 1 and fig. 2A through 2K.

At step 110, a semiconductor-on-insulator substrate 210 is provided. As shown in fig. 2A, the semiconductor-on-insulator substrate 210 includes a first substrate 212, an insulating layer 214 on the first substrate 212, and a semiconductor layer 216 on the insulating layer 214.

In some embodiments, the semiconductor-on-insulator substrate 210 may be a silicon-on-insulator (SOI) substrate. SOI substrates are readily commercially available and have good properties for integrated photonic devices. In such embodiments, the first substrate 212 may be made of any suitable material (e.g., silicon or germanium). The insulating layer 214 may be an oxide material, a thermal oxide material, a nitride material, or the like. The insulating layer 214 may be silicon dioxide, for example. In an example, the insulating layer 214 may have a thickness of about 1 μm to 5 μm. Semiconductor layer 216 may be referred to as a semiconductor device layer in which various semiconductor components are formed. In some embodiments, the semiconductor layer 216 may be made of silicon, but the present disclosure is not limited thereto. In an example, the semiconductor layer 216 may have a thickness of about 200nm to 250 nm.

In some embodiments, as shown in fig. 2A, an additional optional feature, barrier layer 218, is shown in addition to the structure of the semiconductor-on-insulator substrate 210. The barrier layer 218 may be formed in an optional step after step 110. For example, in accordance with some embodiments, after providing the semiconductor-on-insulator substrate 210, a barrier layer 218 may be formed on the semiconductor layer 216. According to some embodiments, the material forming the barrier layer 218 may be titanium nitride or polysilicon. It should be understood that other materials for the barrier layer 218 are possible.

At step 120, the semiconductor layer 216 is patterned to form a first waveguide 220, as shown in FIG. 2B.

In some examples, semiconductor layer 216 may be patterned by photolithography and etching, among other processes. For example, in an embodiment where the semiconductor-on-insulator substrate 210 is a standard SOI substrate, a photoresist pattern for the first waveguide is formed on the semiconductor-on-insulator substrate 210 by steps such as photoresist throwing, exposing, developing, baking, and the like. Then, the semiconductor layer 216 is etched by an etching process using the photoresist as a mask to form the first waveguide 220. Subsequently, resist stripping and cleaning are performed. The etching process may be, for example, wet etching or dry etching. Wet etching can be classified into isotropic etching and anisotropic etching depending on the etching rate in different crystal directions in an etching liquid. Dry etching employs physical methods (e.g., sputtering, ion etching) or chemical methods (e.g., reactive ion etching).

It should be understood that the above-described manner of patterning the semiconductor layer to form the first waveguide is merely an example, and the present disclosure is not limited thereto. Any suitable process that is capable of patterning the semiconductor layer may be selected according to the particular application and/or requirements.

As described above, in accordance with some embodiments, after providing the semiconductor-on-insulator substrate 210, a barrier layer 218 may be formed on the semiconductor layer 216. That is, the barrier layer 218 may be formed on the semiconductor layer 216 prior to patterning the semiconductor layer 216.

Fig. 2B shows the barrier layer 218 formed. As shown in fig. 2B, in embodiments in which the barrier layer 218 is formed, patterning the semiconductor layer 216 to form the first waveguide 220 may include: the barrier layer 218 and the semiconductor layer 216 are patterned to form a first waveguide 220.

According to some embodiments, the first waveguide 220 may be formed of a material selected from the group consisting of: silicon, silicon oxynitride, silicon nitride, lithium niobate, polymers, and indium phosphide (InP). The first waveguide formed by the materials can be compatible with the existing semiconductor process, such as a CMOS process, and the process cost is reduced.

At step 130, a first dielectric layer 223 is formed on insulating layer 214, as shown in fig. 2C.

As described above, according to some embodiments, the barrier layer 218 may be formed on the semiconductor layer 216 prior to patterning the semiconductor layer 216. In embodiments where barrier layer 218 is formed, as shown in fig. 2C and 2D, a first dielectric layer 223 is formed on insulating layer 214, including: forming a first dielectric material layer 222 overlying the barrier layer 218 and the insulating layer 214; and planarizing the first dielectric material layer 222 until the barrier layer 218 is completely removed, thereby forming a first dielectric layer 223. A surface of the first dielectric layer 223 remote from the first substrate 212 is substantially flush with a surface of the first waveguide 220 remote from the first substrate 212. Fig. 2D shows a schematic representation after forming a first dielectric material layer 222 overlying the barrier layer 218 and the insulating layer 214. It should be understood that although the first dielectric material layer 222 is shown in fig. 2D as having a planar interface, it is understood that in an actual manufacturing process, its surface may not be planar due to the effects of its manufacturing process. Thus, it may be desirable to planarize the first dielectric material layer 222 to obtain a substantially smooth, planar surface.

A surface of the first dielectric layer 223 remote from the first substrate 212 is substantially flush with a surface of the first waveguide 220 remote from the first substrate 212. For example, referring to the orientation shown in FIG. 2D, the upper surface of the first dielectric layer 223 is substantially flush with the upper surface of the first waveguide 220.

In the present disclosure, the term "substantially flush" encompasses "flush" and deviations from "flush" due to errors caused by the manufacturing process. It will be appreciated that it is possible for the surfaces of the first dielectric layer and the first waveguide to float up and down within their tolerances, but to be substantially smooth planar, given the manufacturing process.

According to some embodiments, the first dielectric material layer 222 may be formed by deposition and the first dielectric material layer 222 may be planarized by chemical mechanical polishing until the barrier layer 218 is completely removed, resulting in a smooth surface.

In the above-described embodiment including the blocking layer 218, the blocking layer 218 may protect the first waveguide 220 from being damaged during the planarization process and may act as a stop layer for the planarization process, i.e., the planarization process may be stopped after the blocking layer 218 is completely removed. Thereby, the smoothness of the upper surface of the first dielectric layer 223 can be ensured, and the first waveguide 220 can be protected from being damaged in the planarization process.

According to some embodiments, the first dielectric layer 223 may be formed of a material selected from the group consisting of: oxides, oxynitrides, and polymers. For example, the first dielectric layer 223 may be formed of an optical epoxy. According to another example, the first dielectric layer may be formed of silicon dioxide.

At step 140, a second dielectric layer 224 is formed over the first dielectric layer 223 and the first waveguide 220, as shown in FIG. 2E.

In some examples, the second dielectric layer 224 may be formed by deposition on the first dielectric layer 223 and the first waveguide 220.

According to some embodiments, second dielectric layer 224 may be formed of a material selected from the group consisting of: oxides, thermal oxides, and nitrides. For example, the material of the second dielectric layer 224 may be silicon dioxide. It is understood that other materials for forming the second dielectric layer are possible and not limited thereto.

The second dielectric layer 224 may, for example, serve as a spacer layer between the first waveguide 220 and a second waveguide (described later). According to some embodiments, the thickness of the second dielectric layer may be determined based on at least the material of the first waveguide, the material of the second dielectric layer, and the expected coupling efficiency. For example, to achieve the coupling efficiency required for evanescent field coupling between the first waveguide and the second waveguide, the thickness of the second dielectric layer at which the required coupling efficiency (e.g., the optimal coupling efficiency) is satisfied may be calculated by a finite difference time domain method (FDTD) after the material of the second dielectric layer and the materials and structures of the first waveguide and the second waveguide are selected.

As described above, after the first dielectric layer 223 is formed, the second dielectric layer 224 is formed on the first dielectric layer 223 and the first waveguide 220. That is, the first dielectric layer 223 and the second dielectric layer 224 are formed separately. Forming two dielectric layers separately facilitates obtaining a thickness of the second dielectric layer 224 within an ideal range, as compared to a case where one dielectric layer is integrally formed by the same material to cover the first waveguide, thereby satisfying a desired design requirement and improving coupling efficiency. In addition, as the material for forming the first dielectric layer and the material for forming the second dielectric layer can be respectively selected, flexible design can be realized, which is beneficial to meeting the requirements of different applications.

At step 150, a second waveguide 228 is formed on the second dielectric layer 224, as shown in FIG. 2G.

According to some embodiments, forming a second waveguide 228 on the second dielectric layer 224 includes: forming a second waveguide material layer 226 on the second dielectric layer 224; and patterning the second waveguide material layer 226 to form second waveguides 228, as shown in fig. 2F and 2G.

According to some embodiments, the second waveguide 228 may be formed of silicon nitride or silicon oxynitride. The second waveguide formed of silicon nitride or silicon oxynitride can be compatible with existing semiconductor processes, such as CMOS processes. In addition, the second waveguide formed of silicon nitride or silicon oxynitride can reduce the accuracy requirement of the lithography machine, and thus can further reduce the process cost.

According to some examples, the second waveguide material layer 226 may be formed on the second dielectric layer 224 by LPCVD (low pressure chemical vapor deposition) or PECVD (plasma enhanced chemical vapor deposition). Then, on the formed second waveguide material layer 226, a photoresist pattern for the second waveguide 228 is formed through the steps of spin coating, exposing, developing, baking, and the like. Subsequently, the second waveguide material layer 226 is etched using the photoresist as a mask to pattern the second waveguide material layer 226 to form a second waveguide 228. And then removing the photoresist and cleaning.

It should be understood that the manner in which the second waveguide is formed described above is merely exemplary, and the present disclosure is not limited thereto. Any suitable process capable of forming the second waveguide 228 may be selected according to the particular application and/or requirements.

At step 160, a third dielectric layer 234 is formed overlying second waveguide 228, as shown in FIG. 2H.

The third dielectric layer 234 may be used, for example, as an upper cladding layer of an end-face coupler. According to some embodiments, the third dielectric layer 234 may be formed of a material selected from the group consisting of: oxides, thermal oxides, and nitrides. For example, the third dielectric layer 234 may be formed using a silicon dioxide material.

According to some example embodiments, the material forming the third dielectric layer 234 may be the same as the material forming the first dielectric layer 223. Optionally, after forming the third dielectric layer 234, a planarization process, such as chemical mechanical polishing, may be utilized to planarize the surface of the third dielectric layer 234.

At step 170, the third dielectric layer 234 is bonded to a carrier substrate 236 at a side of the third dielectric layer 234 remote from the second waveguide 228, as shown in FIG. 2I.

In some examples, carrier substrate 236 may be made of any suitable material, including but not limited to silicon, germanium, glass, or ceramic, and the like, without limitation.

Fig. 2I shows the carrier substrate 236 after bonding to the upper surface of the third dielectric layer 234. As will be described later, the carrier substrate 236 may provide support during subsequent removal of the first substrate to avoid damage to already formed waveguide structures and the like.

At step 180, the first substrate 212 is removed, as shown in FIG. 2J.

In some examples, the first substrate 212 may be removed using any suitable technique, including but not limited to grinding, lapping, Chemical Mechanical Polishing (CMP), dry polishing (dry polishing), electrochemical etching (electrochemical etching), wet etching (wet etching), Plasma Assisted Chemical Etching (PACE), atmospheric plasma etching (ADPE), and the like. By removing the first substrate 212, smaller size of the end-face coupler can be achieved and contribute to improved electrical and thermal performance.

In some embodiments, the structure shown in fig. 2I may be flipped and then the first substrate 212 removed.

At step 190, a fourth dielectric layer 238 is formed on the surface of the insulating layer 214, as shown in fig. 2K.

According to some embodiments, the fourth dielectric layer 238 is formed of a material selected from the group consisting of: oxides, thermal oxides, and nitrides. It is understood that other materials for forming the fourth dielectric layer 238 are possible and not limiting herein.

According to some embodiments, the material forming the fourth dielectric layer 238 may be selected to be the same or similar to the refractive index of the material forming the insulating layer 214. Optionally, after forming the fourth dielectric layer 238, a planarization process, such as chemical mechanical polishing, may be utilized to planarize the surface of the fourth dielectric layer 238. The fourth dielectric layer 238 may be used, for example, as a lower cladding layer of an end-face coupler.

Having described embodiments of methods of manufacturing end-couplers, the resulting structure of the end-couplers will be clearly understood. In the following, for completeness, an exemplary embodiment of an end-face coupler is described in connection with fig. 2K. The end-coupler embodiments can provide the same or corresponding advantages as the method embodiments, and a detailed description of these advantages is omitted for the sake of brevity.

According to some embodiments, as shown in fig. 2K, an end-face coupler may comprise: a first waveguide 220; a first dielectric layer 223 adjacent to the first waveguide 220; a second dielectric layer 224 on the first waveguide 220 and the first dielectric layer 223; a second waveguide 228 on the second dielectric layer 224; a third dielectric layer 234 covering the second waveguide 228; a carrier substrate 236 on the third dielectric layer 234; an insulating layer 214 underlying the first waveguide 220 and the first dielectric layer 223; and a fourth dielectric layer 238 underlying the insulating layer 214.

A schematic structure of the second waveguide 228 according to an exemplary embodiment of the present disclosure will be described below with reference to fig. 3. Fig. 3A-3C are schematic diagrams of example structures of the second waveguide 228 according to example embodiments of the present disclosure.

As shown in fig. 3A-3C, according to some embodiments, the second waveguide 228 includes a transition waveguide 232 and a transmission waveguide 230. The conversion waveguide 232 is used for performing the spot-size conversion of the light received from the optical fiber 310 and transmitting the spot-size-converted light to the transmission waveguide 230; at least a portion of the transmission waveguide 230 is vertically aligned with at least a portion of the first waveguide to couple light transmitted in the transmission waveguide 230 into the first waveguide.

According to some embodiments, at least a portion of the transition waveguide 232 tapers in size in a direction perpendicular to the direction of proximity to the optical fiber 310.

According to some embodiments, the conversion waveguide 232 is a linear tapered waveguide, a non-linear tapered waveguide, or a sub-wavelength grating. It should be understood that other configurations of transition waveguides are possible and not limited thereto.

Fig. 3A shows an example where the transition waveguide 232 is a nonlinear tapered waveguide. The nonlinear tapered waveguide 232 tapers in size in a direction perpendicular to the direction of approach to the optical fiber 310 (e.g., the Y-direction). Illustratively, the upper and lower sides of the nonlinear tapered waveguide 232 may be parabolic-like or hyperbolic. It should be understood, however, that other shapes of non-linear tapered waveguides are possible and not limiting herein.

Fig. 3B shows an example where the transition waveguide 232 is a linear tapered waveguide. The linear tapered waveguide 232 gradually decreases in size in a direction perpendicular to the direction of approach to the optical fiber 310 (e.g., the Y direction).

Fig. 3C shows an example where the conversion waveguide 232 is a sub-wavelength grating. The sub-wavelength grating may include a first grating portion 301 and a second grating portion 302. The first grating portion 301 may include a first grating period (also called grating constant) Λ₁The plurality of first grating structure units 3011 are arranged, and the plurality of first grating structure units 3011 are gradually reduced in size in a direction (for example, X direction) close to the optical fiber 310 and in a direction (for example, Y direction) perpendicular to the direction close to the optical fiber 310. The second grating portion 302 may comprise a second grating period Λ₂A plurality of second grating structure units 3021 arranged, and a taper unit 3023 connected to the plurality of second grating structure units 3021. The plurality of second grating structure units 3021 are the same in size, and the tapered unit 3023 is gradually reduced in size in a direction (for example, Y direction) perpendicular to the direction of approaching the optical fiber 310. For example, the tip of the tapered unit 3023 faces the optical fiber.

According to the embodiment of the disclosure, the second waveguide comprises the sub-wavelength grating structure, compared with the waveguide with the traditional tapered structure, the alignment tolerance can be improved, the manufacturing difficulty of the end-face coupler is reduced, and the size of the end-face coupler is reduced.

By changing the size of the grating structure unit and the corresponding duty ratio (the ratio of the grating structure unit to the grating period), the equivalent refractive index of the sub-wavelength grating can be adjusted, so that the optical signal can be gradually converted from an initial large mode field mode spot to a small mode field mode spot which can be bound by the transmission waveguide 230 in the process of transmitting along the sub-wavelength grating, and the mode spot conversion of the light from the optical fiber 310 to the transmission waveguide 230 is realized.

In some embodiments, as shown in fig. 3C, the geometric size of the first grating-structure unit closest to the optical fiber 310 among the plurality of first grating-structure units 3011 may be determined based on the diameter of the mode spot of the optical fiber 310.

In order to better realize the mode spot matching between the sub-wavelength grating and the optical fiber 310, the geometric size of the first grating structure unit closest to the optical fiber 310 in the plurality of first grating structure units 3011 may be set based on the diameter of the mode spot of the light output from the optical fiber 310, so as to improve the matching degree between the sub-wavelength grating and the optical fiber 310. For example, the parameters of the first grating structure unit (i.e., the tip of the sub-wavelength grating 232) closest to the optical fiber 310 in the plurality of first grating structure units 3011 and the optical fiber 310 for maximum mode spot matching can be calculated by the eigenmode simulation method, and the geometric size of the first grating structure unit closest to the optical fiber 310 in the plurality of first grating structure units 3011 is determined based on the parameters.

In some embodiments, the tip of the sub-wavelength grating is spaced from the end-coupler end-face on the same side of the sub-wavelength grating by a distance that ensures high optical quality and high coupling efficiency of the tip of the sub-wavelength grating during the deep etching process to connect the optical fibers.

In some embodiments, the end face of the first grating structure unit closest to the optical fiber 310 in the plurality of first grating structure units 3011 is square. By arranging the end face of the first grating structure unit closest to the optical fiber 310 in the plurality of first grating structure units 3011 to be square, the sub-wavelength grating can be better matched with the end face of an optical fiber such as a standard single-mode optical fiber, so that light in the optical fiber can be transmitted with low polarization loss.

It is understood, however, that other shapes (e.g., rectangular) of the end face of the first grating structure unit closest to the fiber 310 are possible and not limiting.

In some embodiments, the duty cycle of the first grating portion 301 may vary in a direction (e.g., X-direction) closer to the optical fiber 310.

For example, as shown in fig. 3C, it is assumed that the first grating period (also referred to as a grating constant) of the first grating portion 301 is Λ₁. The first grating structure unit 3011 is shown in a black portion in fig. 3C. Duty ratio of the first grating portion 301 (first grating structure unit 3011 and first grating period Λ)₁Ratio) is changed along the X direction. Illustratively, the duty cycle of the first grating portion 301 may be smaller as it gets closer to the optical fiber 310. With such an arrangement, the equivalent refractive index of the sub-wavelength grating can be made higher in a direction away from the optical fiber 310, thereby facilitating conversion of a large mode field pattern spot into a small mode field pattern spot. Illustratively, the change in the equivalent refractive index of the sub-wavelength grating may be linear or non-linear.

The mode spot conversion efficiency of a sub-wavelength grating is related to the mode field size of the fiber, the material and the structure of the sub-wavelength grating. The structural parameters of the sub-wavelength grating, such as the size of the grating structural unit and the corresponding duty ratio, when the coupling efficiency requirement (e.g., the optimal coupling efficiency) is satisfied, can be calculated by a finite difference time domain method (FDTD) after the fiber specification and the material of the sub-wavelength grating are selected.

In some embodiments, the duty cycle of the second grating portion 302 may remain unchanged.

In some embodiments, the first grating period may be equal to the second grating period. For example, the first grating period is shown in FIG. 3C as Λ₁Showing the second grating period as Λ₂. First grating period Λ₁May be related to the second grating period Λ₂The same is true. In other embodiments, the first grating period Λ₁Or with the second grating period Λ₂Are not identical. By flexibly setting the relationship between the first grating period and the second grating period, the flexible control of the mode spot of the transmission light can be realized.

Light in the optical fiber propagates through the sub-wavelength grating into the transmission waveguide and through at least a portion of the transmission waveguide into the first waveguide. The transmission of light between the transmission waveguide and the first waveguide will be described below with reference to fig. 4. Fig. 4 is a schematic diagram of a partial structure of an end-face coupler according to an exemplary embodiment of the present disclosure.

In some embodiments, as shown in fig. 4, at least a portion of the transmission waveguide 230 of the second waveguide in the end-face coupler comprises a tapered structure 2301, and at least a portion of the first waveguide 220 comprises a tapered structure 2201. The tapered structure 2301 of the transmission waveguide 230 tapers in a direction away from the optical fiber, and the tapered structure 2201 of the first waveguide 220 tapers in a direction closer to the optical fiber. Fig. 4 also shows the fourth dielectric layer 238, the insulating layer 214, the first dielectric layer 223, the second dielectric layer 224, the third dielectric layer 234, and the carrier substrate 236 of the end-coupler.

The tapered structure 2301 of the transmission waveguide 230 and the tapered structure 2201 of the first waveguide 220 can constitute a vertical coupling structure that can efficiently couple the optical signal in the transmission waveguide 230 into the first waveguide 220.

In some embodiments, the tapered structure of the transmission waveguide and the tapered structure of the first waveguide may be linearly tapered structures, hyperbolic tapered structures, or parabolic-like tapered structures.

As shown in fig. 4, by gradually decreasing the width of the tapered structure 2301 of the transmission waveguide 230, the optical signal mode spot transmitted in the transmission waveguide 230 becomes gradually larger, so that the optical signal can be coupled with the tapered structure 2201 of the first waveguide 220 by the mode of the evanescent field. The light coupled into the tapered structure 2201 is gradually converted into a mode that can be bound by the first waveguide 220 due to the change in the width of the tapered structure 2201, thereby finally achieving efficient optical coupling of the optical fiber to the first waveguide 220.

Illustratively, as shown in the lower half of fig. 4, the tapered structure 2301 of the transmission waveguide 230 and the tapered structure 2201 of the first waveguide 220 may be aligned in the X-Y plane. For example, in the X direction, the two tapered structures have the same length, and in the Y direction, the two tapered structures are disposed to overlap.

According to an exemplary embodiment of the present disclosure, there is also provided an end face coupler, which may be manufactured by the above-described method.

In some embodiments, the operating band of the end-face coupler formed by the manufacturing method according to the exemplary embodiment of the present disclosure may be an O-band, an S-band, a C-band, or an L-band.

In some embodiments, the total length of the end-face coupler may be determined based on the coupling efficiency between the end-face coupler and the optical fiber. For example, the total length of the end-face coupler at which a desired coupling efficiency (e.g., a maximum coupling efficiency) is satisfied can be calculated by a finite difference time domain method (FDTD).

The polarization mode of an end-face coupler fabricated according to the method of exemplary embodiments of the present disclosure may be configured to support one of the group consisting of: TE mold; TM mode; and both TE and TM modes. Therefore, the end face coupler can be applied to various modes, and the application range of the coupler is enlarged.

While the disclosure has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative and exemplary and not restrictive; the present disclosure is not limited to the disclosed embodiments. Variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed subject matter, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word "comprising" does not exclude other elements or steps not listed, the indefinite article "a" or "an" does not exclude a plurality, and the term "a plurality" means two or more. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.

Aspect 1 is a method of manufacturing an end-face coupler, comprising:

providing a semiconductor-on-insulator substrate comprising a first substrate, an insulating layer on the first substrate, and a semiconductor layer on the insulating layer;

patterning the semiconductor layer to form a first waveguide;

forming a first dielectric layer on the insulating layer;

forming a second dielectric layer on the first dielectric layer and the first waveguide;

forming a second waveguide on the second dielectric layer;

forming a third dielectric layer covering the second waveguide;

bonding the third dielectric layer to a carrier substrate on a side of the third dielectric layer remote from the second waveguide;

removing the first substrate; and

and forming a fourth dielectric layer on the surface of the insulating layer.

Aspect 2 the method of aspect 1, further comprising: forming a barrier layer on the semiconductor layer prior to patterning the semiconductor layer,

wherein patterning the semiconductor layer to form a first waveguide comprises:

patterning the barrier layer and the semiconductor layer to form the first waveguide.

Aspect 3 the method of aspect 2, wherein forming a first dielectric layer on the insulating layer comprises:

forming a first dielectric material layer covering the barrier layer and the insulating layer; and

planarizing the first dielectric material layer until the barrier layer is completely removed to form the first dielectric layer,

wherein a surface of the first dielectric layer distal from the first substrate is substantially flush with a surface of the first waveguide distal from the first substrate.

Aspect 4 the method of aspect 1, wherein forming a second waveguide on the second dielectric layer comprises:

forming a second waveguide material layer on the second dielectric layer; and

patterning the second waveguide material layer to form the second waveguide.

Aspect 5 the method of aspect 1, wherein the first waveguide is formed from a material selected from the group consisting of: silicon, silicon oxynitride, silicon nitride, lithium niobate, polymers, and indium phosphide.

Aspect 6 the method of aspect 1, wherein the second waveguide is formed of silicon nitride or silicon oxynitride.

Aspect 7 the method of aspect 1, wherein the first dielectric layer is formed of a material selected from the group consisting of: oxides, oxynitrides, and polymers.

The method of aspect 1, wherein the second, third and fourth dielectric layers are formed of a material selected from the group consisting of: oxides, thermal oxides, and nitrides.

Aspect 9 an end-face coupler, comprising:

a first waveguide;

a first dielectric layer adjacent to the first waveguide;

a second dielectric layer on the first waveguide and the first dielectric layer;

a second waveguide on the second dielectric layer;

a third dielectric layer covering the second waveguide;

a carrier substrate on the third dielectric layer;

an insulating layer located below the first waveguide and the first dielectric layer; and

and the fourth dielectric layer is positioned below the insulating layer.

Aspect 10 the end-face coupler of aspect 9, wherein the second waveguide comprises a transition waveguide and a transmission waveguide, wherein,

the conversion waveguide is used for performing mode spot conversion on light received from the optical fiber and transmitting the mode spot converted light to the transmission waveguide; and

at least a portion of the transmission waveguide is vertically aligned with at least a portion of the first waveguide to couple light transmitted in the transmission waveguide into the first waveguide.

Aspect 11 the end-face coupler of aspect 10, wherein,

at least a portion of the transition waveguide tapers in size in a direction perpendicular to a direction of proximity to the optical fiber.

Aspect 12 the end-face coupler of aspect 11, wherein the conversion waveguide is a linear tapered waveguide, a non-linear tapered waveguide, or a sub-wavelength grating.

Aspect 13 the end-face coupler of aspect 12, wherein the conversion waveguide is a sub-wavelength grating, and

wherein the sub-wavelength grating includes a first grating portion and a second grating portion,

wherein the first grating portion includes a plurality of first grating structure units arranged at a first grating period, the plurality of first grating structure units being gradually reduced in size in a direction approaching the optical fiber and in a direction perpendicular to the direction approaching the optical fiber, and

wherein the second grating portion includes a plurality of second grating structure units arranged at a second grating period and a tapered unit connected to the plurality of second grating structure units, the plurality of second grating structure units are the same in size, and the tapered unit is tapered in a direction approaching the optical fiber.

Aspect 14 the end-face coupler of aspect 13, wherein,

the geometric size of a first grating structure unit of the plurality of first grating structure units, which is closest to the optical fiber, is determined based on a spot diameter of the optical fiber.

Aspect 15 the end-face coupler of aspect 13, wherein,

the end face of the first grating structure unit closest to the optical fiber in the plurality of first grating structure units is square.

Aspect 16 the end-face coupler of aspect 13, wherein,

the duty ratio of the first grating portion varies in a direction approaching the optical fiber.

Aspect 17 the end-face coupler of aspect 13, wherein,

the duty cycle of the second grating portion remains unchanged.

Aspect 18 the end-face coupler of aspect 13, wherein,

the first grating period is equal to the second grating period.

Aspect 19 the end-face coupler of aspect 10, wherein,

the at least a portion of the transmission waveguide comprises a tapered structure and the at least a portion of the first waveguide comprises a tapered structure, an

Wherein the tapered structure of the transmission waveguide tapers in a direction away from the optical fiber and the tapered structure of the first waveguide tapers in a direction closer to the optical fiber.

Aspect 20 the end-face coupler of aspect 19, wherein,

the tapered structure of the transmission waveguide and the tapered structure of the first waveguide are linearly tapered structures, hyperbolic tapered structures or parabolic tapered structures.