Optical package substrate, optical device, optical module, and method for molding optical package substrate

Abstract

Micro-discharge machining is employed to obtain a die, and an optical package substrate is produced by press formation using such a die. An optical fiber, an optical waveguide, a lens, an isolator, an optical filter and a light receiving/emitting element are mounted by passive alignment.

1 - 60 . (canceled)  
   
   
       61 . An optical device comprising: 
 an optical package substrate including 
 (i) an optical-fiber-positioning guide groove formed to a precision of sub-microns, said optical-fiber-positioning guide groove extending in a surface of said optical package substrate from a predetermined side surface thereof to a predetermined location thereon; and  
 (ii) a lens-positioning guide groove formed to a precision of sub-microns, said lens-positioning guide groove extending in the surface of the optical package substrate from another side surface thereof, opposite to the predetermined side surface, to the predetermined location;  
   a lens affixed to said lens-positioning guide groove; and    an optical fiber affixed to said optical-fiber-positioning guide groove such that an optical axis of said optical fiber is aligned with an optical axis of said lens.    
   
   
       62 . An optical device comprising: 
 an optical package substrate including 
 (i) an optical-fiber-positioning guide groove formed to a precision of sub-microns, said optical-fiber-positioning guide groove extending in a surface of said optical package substrate from a predetermined side surface thereof to a predetermined location thereon, and  
 (ii) a lens-positioning guide depression, in the surface of said optical package substrate, formed to a precision of sub-microns;  
   a lens affixed to said lens-positioning guide depression; and    an optical fiber affixed to said optical-fiber-positioning guide groove such that an optical axis of said optical fiber is aligned with an optical axis of said lens.    
   
   
       63 . An optical device comprising: 
 an optical package substrate including 
 (i) an optical-fiber-positioning guide groove formed to precision of sub-microns, said optical-fiber-positioning guide groove extending in a surface of said optical package substrate from a predetermined side surface thereof to a predetermined location thereon, and  
 (ii) an optical-component-positioning guide depression, in the surface of said optical package substrate, formed to a precision of sub-microns;  
   an optical fiber affixed to said optical-fiber-positioning guide groove; and    an optical component affixed to said optical-component-positioning guide depression such that an optical axis of said optical fiber is aligned with an optical axis of said optical component,    wherein said optical-component-positioning guide depression extends in a direction perpendicular to the optical axis of said optical fiber.    
   
   
       64 . An optical device comprising: 
 an optical package substrate including 
 (i) an optical-fiber-positioning guide groove formed to a precision of sub-microns, said optical-fiber-positioning guide groove extending in a surface of said optical package substrate from a predetermined side surface thereof to a predetermined location thereon,  
 (ii) an optical-component-positioning guide depression, in the surface of said optical package substrate, formed to a precision of sub-microns, and  
 (iii) a lens-positioning guide groove, in the surface of said optical package substrate, formed to a precision of sub-microns;  
   an optical fiber affixed to said optical-fiber-positioning guide groove,    an optical component affixed to said optical-component-positioning guide depression, and    a lens affixed to said lens-positioning guide groove such that respective optical axes of said optical fiber, said optical component and said lens are aligned with one another,    wherein said optical-component-positioning guide depression extends in a direction perpendicular to the optical axis of said optical fiber.    
   
   
       65 . An optical device comprising: 
 an optical package substrate including 
 (i) a first optical-fiber-positioning guide groove formed to a precision of sub-microns, said first optical-fiber-positioning guide groove extending in a surface of said optical package substrate from a predetermined side surface thereof to a predetermined location thereon,  
 (ii) a second optical-fiber-positioning guide groove formed to a precision of sub-microns, said second optical-fiber-positioning guide groove extending in the surface of said optical package substrate from another side surface thereof, opposite to the predetermined side surface, to the predetermined location,  
 (iii) a third optical-fiber-positioning guide groove formed to a precision sub-microns, said third optical-fiber-positioning guide groove extending in the surface of said optical package substrate parallel to said first and second optical-fiber-positioning guide grooves, and  
 (iv) an optical-component-positioning guide depression formed to a precision of sub-microns, said optical-component-positioning guide depression extending in the surface of said optical package substrate between said first and second optical-fiber-positioning guide grooves;  
   an optical component affixed to said optical-component-positioning guide depression;    a first optical fiber affixed to said first optical-fiber-positioning guide groove and abutted against said optical component;    a second optical fiber affixed to said second optical-fiber-positioning guide groove and abutted against said optical component such that respective optical axes of said first optical fiber, said second optical fiber and said optical component are aligned with one another; and    a third optical fiber affixed to said third optical-fiber-positioning guide groove,    wherein said optical-component-positioning guide depression extends in a direction perpendicular to the respective optical axes of said first and second optical fibers.    
   
   
       66 . An optical device comprising: 
 an optical package substrate including 
 (i) a waveguide groove corresponding to a predetermined optical waveguide core pattern, said waveguide groove extending in a surface of said optical package substrate from a predetermined side surface thereof to a predetermined location thereon, and  
 (ii) a lens-positioning guide groove extending in the surface of said optical package substrate from another side surface thereof, opposite to the predetermined side surface, to the predetermined location;  
   an optical waveguide defined by core material in said waveguide groove;    a lens affixed to said lens-positioning guide groove such that an optical axis of said lens is aligned with an optical axis of said optical waveguide; and    a substrate attached to said optical package substrate via an adhesive so as to cover said waveguide groove,    wherein said core material has a higher refractive index than a refractive index of material of said optical package substrate, and said adhesive has a lower refractive index than the refractive index of said core material.    
   
   
       67 . An optical device comprising: 
 an optical package substrate including 
 (i) a waveguide groove corresponding to a predetermined optical waveguide core pattern, said waveguide groove extending in a surface of said optical package substrate from a predetermined side surface thereof to a predetermined location thereon, and  
 (ii) an optical-component-positioning guide depression in the surface of said optical package substrate;  
   an optical fiber;    an optical component affixed to said optical-component-positioning guide depression such that an optical axis of said optical component is aligned with an optical axis of said optical fiber;    an optical waveguide defined by core material in said waveguide groove; and    a substrate attached to said optical package substrate via an adhesive so as to cover said waveguide groove,    wherein said optical-component-positioning guide depression extends in a direction perpendicular to an optical axis of said optical waveguide, and    wherein said core material has a higher refractive index than a refractive index of material of said optical package substrate, and said adhesive has a lower refractive index than the refractive index of said core material.    
   
   
       68 . An optical module comprising: 
 an optical package substrate including 
 (i) a waveguide groove, corresponding to a predetermined optical waveguide core pattern, in a surface of said optical package substrate,  
 (ii) an optical-component-positioning guide depression in the surface of said optical package substrate,  
 (iii) a lens-positioning guide groove in the surface of said optical package substrate,  
 (iv) a first stage on the surface of said optical package substrate, and  
 (v) a second stage on the surface of said optical package substrate;  
   an optical waveguide defined by core material in said waveguide groove;    an isolator or an optical filter affixed to said optical-component positioning guide depression such that an optical axis of said isolator or optical filter is aligned with an optical axis of said optical waveguide;    a lens affixed to said lens-positioning guide groove such that an optical axis of said lens is aligned with the optical axis of said optical waveguide;    a light emitting element affixed to said first stage such that an optical axis of said light emitting element is aligned with the optical axis of said optical waveguide;    a light receiving element affixed to said second stage such that an optical axis of said light receiving element is aligned with an optical axis of said optical waveguide; and    a substrate attached to said optical package substrate via an adhesive so as to cover said waveguide groove,    wherein said optical-component-positioning guide depression extends in a direction perpendicular to the optical axis of said optical waveguide that is aligned with the optical axis of said isolator or optical filter, and    wherein said core material has a higher refractive index than a refractive index of material of said optical package substrate, and said adhesive has a lower refractive index than the refractive index of said core material.    
   
   
       69 . The optical module according to  claim 68 , wherein the optical waveguide core pattern corresponds to a waveguide diverging into branches, and said optical-component-positioning guide depression is provided for one of the branches so as to extend in a direction perpendicular to an optical axis of the one of the branches.  
   
   
       70 . An optical device comprising: 
 an optical package substrate including 
 (i) at least one optical-fiber-positioning guide groove extending in a surface of said optical package substrate from a predetermined side surface thereof to a predetermined location thereon, and  
 (ii) a substrate-positioning depression in the surface of said optical package substrate and adjoining said at least one optical-fiber-positioning guide groove at the predetermined location;  
   at least one optical fiber affixed to said at least one optical-fiber-positioning guide groove;    an optical waveguide substrate affixed to said substrate-positioning depression, said optical waveguide substrate having a waveguide groove that is molded therein and corresponds to an optical waveguide core pattern;    core material in said waveguide groove; and    a substrate attached to said optical package substrate via an adhesive so as to cover said waveguide groove,    wherein said core material has a higher refractive index than a refractive index of material of said optical package substrate and a refractive index of material of said optical waveguide substrate, and said adhesive has a lower refractive index than the refractive index of said core material.    
   
   
       71 . An optical device comprising: 
 an optical package substrate including 
 (i) at least one optical-fiber-positioning guide groove extending in a surface of said optical package substrate from a predetermined side surface thereof to a predetermined location thereon, and  
 (ii) a depression in the surface of said optical package substrate and adjoining said at least one optical-fiber-positioning groove at the predetermined location;  
   at least one waveguide section corresponding to an optical waveguide core pattern, said at least one waveguide section being on a surface defining said depression;    core material in said at least one waveguide section;    at least one optical fiber mounted to said at least one optical-fiber-positioning guide groove, said at least one optical fiber being aligned with an optical axis of said at least one waveguide section; and    an optical-fiber-fixing substrate affixed to said at least one optical fiber via an adhesive,    wherein said core material has a higher refractive index than a refractive index of material of said optical package substrate, and said adhesive has a lower refractive index than the refractive index of said core material.