Light Source, MEMS Optical Switch, Sensor and Methods for Manufacturing the Same
20240192573 ยท 2024-06-13
Inventors
- Johan Willem Berenschot (Enschede, NL)
- Sonia Maria Garcia Blanco (Enschede, NL)
- Simen Mikalsen Martinussen (Enschede, NL)
- Niels Roelof Tas (Enschede, NL)
- Roald Michel Tiggelaar (Enschede, NL)
Cpc classification
G02B26/0841
PHYSICS
G02F1/01
PHYSICS
G02F2203/15
PHYSICS
G02F1/0126
PHYSICS
G02F1/3511
PHYSICS
International classification
Abstract
The present invention relates to a light source for generating an optical frequency comb. The present invention further relates to a method for manufacturing the optical resonator used in this light source. The present invention additionally relates to microelectromechanical systems, MEMS, optical switch and system comprising the same. The present invention also relates to a sensor and to a method for manufacturing a suspended silicon nitride structure comprised in the sensor. According to the present invention, a single-step LPCVD deposited monolithic stoichiometric Si.sub.3N.sub.4 layer is used on a mono-crystalline aluminum oxide substrate such as sapphire. The thickness of the Si.sub.3N.sub.4 layer exceeds 500 nm. This layer can be realized with relatively low residual stress.
Claims
1. A light source for generating an optical frequency comb, comprising: an optical resonator, comprising: a mono-crystalline aluminum oxide substrate; an input waveguide; an output waveguide; a closed-loop waveguide arranged on the substrate, and optically coupled to the input waveguide and output waveguide, wherein the closed-loop waveguide is configured for: receiving at least a part of a beam of light from the input waveguide; accumulating optical energy inside the closed-loop waveguide using the received beam of light; generating an optical frequency comb using the accumulated optical energy; coupling at least a part of the generated optical frequency comb to the output waveguide; wherein the closed-loop waveguide is a monolithic silicon nitride waveguide having a thickness of 500 nm or more, and which is deposited on the substrate.
2. The light source according to claim 1, further comprising a laser source for transmitting a beam of light into the input waveguide.
3. The light source according to claim 2, wherein the laser source is a continuous-wave laser.
4. The light source according to any claim 2 or 3, wherein laser source is configured to generate a light beam at a first frequency, and wherein the closed-loop waveguide is configured to generate said frequency comb to have equidistantly arranged frequency components around the first frequency.
5. The light source according to claim 1, wherein the closed-loop waveguide is configured to generate a Kerr optical frequency comb.
6. The light source according to claim 1, wherein the silicon nitride waveguide has a thickness of 750 nm or more.
7. The light source according to claim 1, wherein the silicon nitride waveguide comprises a SiXNY layer, wherein 0.71<=(X/Y)<=0.76.
8. The light source according to claim 1, wherein the mono-crystalline aluminum oxide substrate comprises a sapphire substrate.
9. The light source according to claim 1, wherein the monolithic silicon nitride waveguide is deposited directly on the mono-crystalline aluminum oxide substrate.
10. The light source according to claim 1, wherein the monolithic silicon nitride waveguide is deposited on the mono-crystalline aluminum oxide substrate via an intermediate layer, wherein a thickness ratio between a thickness of the mono-crystalline aluminum oxide substrate and the intermediate layer exceeds 100:1.
11. The light source according to claim 1, wherein the closed-loop waveguide, the input waveguide and/or the output waveguide, is a ridge waveguide.
12. The light source according to claim 1, wherein at least one of the input waveguide and the output waveguide is a silicon nitride waveguide formed during the same process as the silicon nitride waveguide of the closed-loop waveguide.
13. The light source according to claim 1, wherein the input waveguide and output waveguide are part of a same waveguide.
14. The light source according to claim 1 any of the claims 1-12, wherein the input waveguide and output waveguide are arranged on different and preferably opposite sides of the closed-loop waveguide.
15. A method for manufacturing the optical resonator according to claim 1, the method comprising: providing a mono-crystalline aluminum oxide substrate; depositing a monolithic silicon nitride film of at least 500 nm thick on the substrate in a single-step low-pressure chemical vapor deposition, LPCVD, process at a temperature between 750 and 950 0C; providing a masking layer on top of the deposited silicon nitride film; patterning the masking layer; etching the silicon nitride film using the patterned masking layer to thereby form at least the closed-loop waveguide, and preferably all, among the input waveguide, output waveguide, and closed-loop waveguide.
16. The method according to claim 15, wherein the deposited silicon nitride layer has a thickness of 750 nm or more.
17. The method according to claim 15, wherein the silicon nitride layer, SiXNY, has a composition in which 0.71<=(X/Y)<=0.76.
18. The method according to claim 15, wherein the mono-crystalline aluminum oxide substrate comprises a sapphire substrate.
19. A microelectromechanical system (MEMS) optical switch, comprising: a mono-crystalline aluminum oxide substrate; a monolithic silicon nitride optical waveguide having a thickness of 500 nm or more, and which is deposited on the substrate, said optical waveguide comprising: a base part deposited onto the substrate, wherein the first base is configured to receive a beam of light, and a suspended part having a first end at which the suspended part is integrally connected to the base part and a second end configured to emit said beam of light; a light reception unit comprising an optical waveguide; an actuator configured for displacing the second end relative to the light reception unit in response to an actuation signal to allow or prevent the light beam emitted by the second end to enter the optical waveguide of the light reception unit.
20. The MEMS optical switch according to claim 19, wherein the light reception unit comprises a plurality of optical waveguides, wherein the actuator is configured to, in response to the actuation signal, select one optical waveguide among the plurality of optical waveguides in which the light beam emitted by the second end is allowed to enter.
21.-56. (canceled)
Description
[0058] Next, the present invention will be described in more detail by referring to the appended drawings, wherein:
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[0071] As a next step S1, a single-step low-pressure chemical vapor deposition, LPCVD, process is used to deposit a stoichiometric Si.sub.3N.sub.4 layer 2 on sapphire substrate 1. Typically, NH.sub.3 and SiH.sub.2Cl.sub.2 are used as precursors in a flow ratio of 3:1, and a deposition temperature between 750 and 950? C., preferably between 800 and 850? C., and more preferably around 825? C., is used at a pressure of around 200 mTorr. Thicknesses of Si.sub.3N.sub.4 layer 2 can be in the range between 10 nanometer and 10 micrometer, and are preferably in excess of 750 nm.
[0072] Instead of stoichiometric silicon nitride, a silicon nitride layer Si.sub.xN.sub.y may be deposited that has a composition in which 0.71<=(X/Y)<=0.76.
[0073] As a further step, a photoresist layer 3 is applied onto the deposited Si.sub.3N.sub.4 layer 2. As a next step S2, photolithography techniques are used to define patterns in photoresist layer 3. This is shown in top view and cross-sectional view in
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[0075] The first step of this method is identical to that of
[0076] As a next step S4, a stoichiometric Si.sub.3N.sub.4 layer 2 is deposited on sapphire substrate 1 using the LPCVD process of
[0077] The method continues, in step S7, by etching the amorphous silicon underneath Si.sub.3N.sub.4 layer 2 at predefined positions on substrate 1. In this respect, the amorphous silicon acts as a sacrificial layer. This etching is typically performed using a wet-chemical etching step through the created openings in Si.sub.3N.sub.4 layer 2, for example using Tetramethylammonium hydroxide, TMAH. This etching step causes an under-etch that should be accounted for when designing the mask layers to be used during the lithography step. Furthermore, the composition of Si.sub.3N.sub.4 layer 2 may be non-stoichiometric as explained in connection with
[0078] As shown in
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[0080] Next, in step S10 a single-step LPCVD process is used for depositing a Si.sub.3N.sub.4 layer 2 similar or identical to the deposition process in
[0081] As a next step S13, amorphous silicon layer 4 is removed by means of wet and dry etching. First, a wet-chemical etching step is performed using a wet-chemical etching process using TMAH as illustrated in
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[0083] As a next step, a cleaning step will be performed similar or identical to the step of cleaning substrate 1 in
[0084] In
[0085] In addition, instead of amorphous silicon, sacrificial layers of different sacrificial material can be used.
[0086] Furthermore, if needed, sapphire substrate 1 can be diced into individual dies after completing the above and optionally other processing steps.
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[0088] It should be noted that the tapering illustrated in
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[0090] As shown, the optical switch comprises a sapphire substrate 1. On sapphire substrate 1, a sacrificial SiO.sub.2 layer has been deposited, which has been patterned and selectively removed. In region II, this sacrificial layer is completely removed, whereas regions I indicate a transitional region in which the sacrificial layer has a vertical tapering as discussed in connection with
[0091] The optical switch comprises an input Si.sub.3N.sub.4 ridge waveguide 10 which outside of regions I and II has a part 10A that is directly formed on sapphire substrate 1. Inside region I, waveguide 10 has a part 10B that is gradually lifted away from substrate 1 by an increasingly thicker sacrificial layer. Inside region II, the sacrificial layer has been etched away. Consequently, waveguide 10 comprises a suspended part 10C.
[0092] An output waveguide 11 is arranged opposite to waveguide 10, albeit at a given horizontal clearance. The end facets of waveguides 10 and 11 are shaped to allow a proper optical coupling provided that waveguides 10, 11 are aligned.
[0093] Similar to input waveguide 10, output waveguide 11 comprises a part 11A that is directly contacting sapphire substrate 1 and a part 11B that gradually moves away from sapphire substrate 1 to bring the ends of parts 11B and 10B in vertical alignment.
[0094] Suspended part 10C is fixedly connected to a support beam 12 that is formed of a suspended Si.sub.3N.sub.4 beam. On another end, support beam 12 is connected to a suspended electrode 14A. This electrode comprises a Si.sub.3N.sub.4 base on which an electrode metal layer has been deposited. On opposite sides, suspended electrode 14A is connected to sapphire substrate 1 using Si.sub.3N.sub.4 springs 13A, 13B, which have, similar to input waveguide 10, a part that is directly connected to sapphire substrate 1, a part that is gradually lifted away from substrate 1 by the sacrificial layer, and a part that is suspended above substrate 1.
[0095] Non-suspended electrode 14B comprises a Si.sub.3N.sub.4 base that is arranged on the sacrificial layer, which in turn is deposited on sapphire substrate 1. On top of the Si.sub.3N.sub.4 base, an electrode metal layer has been deposited.
[0096] By applying a voltage between electrodes 14A, 14B, these electrodes can either be pulled together or be pushed apart. The applied voltage thereby forms an actuation signal in dependence of which suspended part 10C performs a lateral movement as indicated by the arrow. In this manner, the optical coupling between input waveguide 10 and output waveguide 11 can be established or broken.
[0097] By arranging a plurality of output waveguides adjacent to one another, a 1?n switch can be realized. More in particular, an optical coupling between the input waveguide and one among the n output waveguides can be established in dependence of the actuation signal.
[0098] A possible drawback of using a support beam 12 as illustrated in
[0099] In even other embodiments, suspended electrode 14A is formed directly on, below or to the side of suspended part 10C. To prevent optical losses, a cladding layer such as a SiO.sub.2 layer can be provided in between suspended part 10C and the metal layer of electrode 14A.
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[0101] Sensing arm 21 comprises a part 21A that is directly arranged on sapphire substrate 1 and a part 21B that is suspended above sapphire substrate 1 by using a sacrificial layer that has been etched away inside region 22. A tapering (not shown) may be used to provide a transition between parts 21A and 21B.
[0102] Light inputted into input Si.sub.3N.sub.4 waveguide 23 is split, preferably equally, over reference arm 20 and sensing arm 21. At output Si.sub.3N.sub.4 waveguide 24, the light from these arms is combined and fed to a light intensity meter (not shown).
[0103] Suspended part 21B of sensing arm 21 may deform. For example, suspended part 21B may bend towards or away from substrate 1. Alternatively or additionally, suspended part 21B may bend in a direction parallel to sapphire substrate 1.
[0104] Regardless the direction of movement, most if not any deformation of suspended part 21B will change the effective refractive index of suspended part 21B. Consequently, the effective optical path length through sensing arm 21 will change whereas the optical path length through reference arm 20 will essentially remain constant.
[0105] In some embodiments, particularly but not necessarily those in which suspended part 21B has a more complex shape than shown, such as a spiral, reference arm 20 can also comprise a suspended part similar to the one described in relation to sensing arm 21 and/or sensing window 22 can extend to both arms of the sensor. This places the reference arm in a more similar environment and therefore allows for it to provide a better reference.
[0106] At output waveguide 24, light from both arms 20, 21 will interfere. Depending on the relative phase offset, the interference can be constructive or destructive. This difference can be determined using the light intensity meter that is connected to output waveguide 24.
[0107] The sensor of
[0108] The bending of sensing arm 21B can be caused by various factors depending on the type of sensor. For example, at least suspended part 21B may be provided with a capturing agent or coating layer for capturing specific species, particles, molecules, pathogens, or the like. Once these species, particles, molecules or pathogens adhere to suspended part 21B, this part may bend as a result of the accumulated weight. In this manner, the sensor can be used as a detector for detecting the presence and/or quantity of adhered particles. In some embodiments, the capturing agent can also be applied onto reference arm 20. In addition, in some embodiments in which the capturing agent is only applied to sensing arm 21, reference arm 20 may also have a suspended part similar to sensing arm 21.
[0109] Suspended part 21B may also bend as a result of an acceleration of the sensor as such. It is therefore possible to use the sensor of
[0110] In
[0111] Sensing arm 21 is depicted as a straight waveguide. Other shapes, such as suspended membranes, suspended interdigitated structures, and suspended spirals are not excluded.
[0112] Although the sensor depicted in
[0113] Next, an application of monolithic silicon nitride on sapphire substrates for non-linear optical applications will be described in more detail by referring to
[0114] Optical resonators using closed-loop waveguides rely on four-wave mixing to generate the optical frequency comb. FWM is the non-linear optical process by which two photons are annihilated and two new photons are created in a non-linear optical material, as illustrated in
[0115] Because FWM is subject to conservation of energy without loss to the material, the energy splitting needs to be symmetric in both cases. The modes will be approximately equally spaced in a resonator with low integrated dispersion, as shown in
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[0117] Closed-loop waveguide 101 in the embodiments shown is a ring resonator or, what is also referred to as a ring cavity. However, waveguide 101 can also take on other shapes such as that of a racetrack waveguide. A racetrack waveguide is a type of closed-loop waveguide comprising a plurality of semi-circular sections and a plurality of linear sections integrally connected in a manner such that the waveguide as a whole loops back on itself.
[0118] The closed-loop waveguide is a stand-alone structure which interacts with its surroundings by optical coupling. This can be achieved in a number of ways, such as directing a laser onto the waveguide directly, via free space or via a fiber directly connected to the waveguide. Such coupling can be enabled by providing waveguide 101 with a prism for in-coupling said laser, or by providing waveguide 101 with coupling gratings. In the embodiments shown, optical coupling is enabled by arranging the coupling sections 102C; 102C, 102C adjacent to closed-loop waveguide 101. When arranged sufficiently close to each other, the coupling sections and the parts of the closed-loop waveguide adjacent thereto together form a directional coupler. Therefore light will jump from coupling sections 102C; 102C, 102C to closed-loop waveguide 101 and vice-versa.
[0119] Closed-loop waveguide 101 is a silicon nitride waveguide deposited onto a mono-crystalline aluminum oxide substrate 100, which preferably comprises a sapphire substrate. Input waveguide 102A and output waveguide 102B can also be fabricated on this material and are preferably ridge type waveguides. However it is also possible for these waveguides to be made of other materials. Closed-loop waveguide 101 has a thickness of 500 nanometer or more. The top down views shown should not be interpreted as providing insight to the height of any of the waveguides. While the other waveguides are preferably as thick as closed-loop waveguide 101, these can also have thicknesses different from that of closed-loop waveguide 101, as well as different from each other. Likewise, widths and lengths of waveguides, as well as distances between them, as shown in
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[0122] In some embodiments, not shown, input waveguide 102A extends beyond coupling section 102C and loops back to integrally connect to the coupling section 102C of the output waveguide 102B. Such an embodiment allows for any input light that leaks beyond coupling section 102C to be part of the ultimately emitted beam of light while in-coupling and out-coupling behavior of the closed-loop waveguide can be configured separately. In some embodiments, not shown, the coupling sections 102C and 102C can be sufficiently long for multiple closed loop waveguides to be arranged in between them, and wherein each of the plurality of closed loop waveguides are optically coupled to the input waveguide and the output waveguide and not optically coupled to one another.
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[0124] In this particular embodiment, light is coupled between the closed-loop waveguides 101A, 101B by the same directional coupling mechanism as described earlier. Consequently, whereas light travels clockwise in closed-loop waveguide 101A, it travels counterclockwise in closed loop waveguide 101B.
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