Abstract: An optical microwave package eliminates launching electrical modes into a microwave strip-line by forming a moat in a housing portion of the package to suppress microwave resonant energy. The moat can be filled with a conductive material to further suppress package resonances. Additionally, the bottom of a substrate positioned within the housing is isolated from any conductive metal to further suppress microwave resonant energy.

Abstract: A device including a first solder pad and a second solder pad comprised of a post-soldering alloy composition on a substrate is provided. The alloy composition comprises two or more elements, and the post soldering alloy composition of the first solder pad has different amounts of the two or more elements than the alloy composition of the second solder pad. A method of making a solder pad comprises masking a substrate comprising at least a first solder pad and a second solder pad, wherein the mask exposes a greater area of the first solder pad so that the deposited element becomes part of an alloy composition of the first solder pad upon soldering thereby changing the melting point of the first solder pad.

Abstract: An optical fiber array having wick stop grooves in a front face of the array. The wick stop grooves control the movement of liquid adhesive (e.g. UV curable adhesive, solder, sol-gel). Particularly, the wick stop grooves prevent liquid adhesive from flowing between the optical fibers in the array and waveguides of an integrated optic chip. Adhesives disposed in the fiber-waveguide optical path can degrade the performance of optical devices. The wick stop grooves can be cut with a dicing saw, or chemically etched (wet or dry), and can have a wide variety of patterns (e.g., straight lines, circles). In any case, the wick stop grooves must prevent the flow of liquid adhesive between the fibers and waveguides. Alternatively, the wick stop grooves are disposed in an edge of the integrated optic chip. Also, the wick stop grooves can be disposed on the front face of other microoptical devices such as filters and lenslet arrays.

Abstract: A system and method for fabricating a thermoelectric cooling (TEC) device and a semiconductor device using such a TEC device are described. Adhesive-containing support structures are used to secure, respectively, positively-doped and negatively-doped TEC elements. The elements are intermeshed and an encapsulating material is applied to the intermeshed array. The support structures are then released and the ends of the encapsulated elements are smoothed and electrically coupled together. If desired, panels are secured to the ends of the elements and a heat sink may also be provided. The TEC device may be used to control and/or tune a laser device.

Abstract: A method and apparatus are disclosed for supporting semiconductor devices on a flexible support which includes one or more thermoelectric cooling devices. The thermoelectric cooling devices, which include at least one pair of positively-doped and negatively-doped elements electrically coupled together, are positioned between a pair of flex panels. Each panel has connector sites at which connectors such as solder balls are located. The thermoelectric cooling devices may be arranged between the panels to create two or more device support areas having different temperature regimes. The thermoelectric cooling devices may be connected to the panels by placing the panels, connectors and thermoelectric cooling devices in a reflow chamber, exposing them to a reducing atmosphere, and heating to a temperature sufficient to reflow the connectors.

Abstract: A microchip is provided having a grayscale feature and a micromachined alignment feature registered to the grayscale feature. A process is also provided to ensure proper registration between the alignment feature and the grayscale feature by using a single exposure mask to define the grayscale feature and the alignment feature. In particular, the exposure mask includes a grayscale pattern representing the grayscale feature and an alignment pattern representing an alignment feature located at a specified position with respect to the grayscale pattern. The alignment pattern in the exposure mask marks the location of the micromachined feature in the microchip. Through a multistep deposition and etching process, the grayscale feature is formed within the substrate along with a micromachined alignment feature to enable the microchip to be mechanically aligned to other components of an optical system while maintaining proper registration of the grayscale feature.

Abstract: The present invention provides a method for forming a vertical taper in a waveguide. In the present invention, a shadow mask is disposed above a waveguide requiring a vertical taper. Then, the waveguide is exposed to a directional etching process (e.g. deep reactive ion etching) while the mask is moved. Ask the mask moves, different regions of the waveguide will be etched different depths, resulting in a vertical taper in the waveguide.

Abstract: An optical assembly which allows for passive alignment of the various elements is described. A substrate with a cut out portion and an upper surface is utilized as a mount for an optical array and an imaging assembly. The optical array, which preferably includes a plurality of optical fibers is positioned on V-grooves located on the upper surface. The imaging assembly, which preferably includes a plurality of lenses, such as GRIN lenses, is lowered at least partially into the cut-out portion. The optical fibers are optically coupled with said lenses. A waveguide, having a plurality of waveguide cores within a cladding, may further be optically coupled with the lenses, or alternatively, directly to the optical fibers. An integrated optic chip may also be affixed to the substrate or mounted on the substrate.

Abstract: An optical fiber switch having two coupled fiber arrays which move in a transverse direction to provide switching action. Each array has a front face and the front faces are nearly in contact. Optical fiber ends are located at the front faces. The front faces of the fiber arrays have transverse grooves in which rolling spheres are disposed. The fiber arrays move by rolling on the spheres. The spheres provide for smooth transverse motion and a fixed distance between optical fiber arrays. The spheres and front face grooves also provide for alignment between the optical fibers.

Abstract: The invention includes an optical fiber device, comprising at least one optical fiber over a substrate, at least one reentrant shape in the substrate adjacent to the optical fiber and a polymer that at least partially encapsulates the optical fiber and attaches the optical fiber to the at least one reentrant shape and methods for making the same.

Abstract: A method and apparatus are disclosed for supporting semiconductor devices on a flexible support which includes one or more thermoelectric cooling devices. The thermoelectric cooling devices, which include at least one pair of positively-doped and negatively-doped elements electrically coupled together, are positioned between a pair of flex panels. Each panel has connector sites at which connectors such as solder balls are located. The thermoelectric cooling devices may be arranged between the panels to create two or more device support areas having different temperature regimes. The thermoelectric cooling devices may be connected to the panels by placing the panels, connectors and thermoelectric cooling devices in a reflow chamber, exposing them to a reducing atmosphere, and heating to a temperature sufficient to reflow the connectors.

Abstract: A system and method for fabricating a thermoelectric cooling (TEC) device and a semiconductor device using such a TEC device are described. Adhesive-containing support structures are used to secure, respectively, positively-doped and negatively-doped TEC elements. The elements are intermeshed and an encapsulating material is applied to the intermeshed array. The support structures are then released and the ends of the encapsulated elements are smoothed and electrically coupled together. If desired, panels are secured to the ends of the elements and a heat sink may also be provided. The TEC device may be used to control and/or tune a laser device.

Abstract: A system and method for optimizing the output of a semiconductor die is described. A lid for a semiconductor package includes a radio frequency resonance dampening material which can be repatterned in real time to minimize resonance reflection within the package. The patterning may take the form of structures within the material or different sections of the material having differing resistivities to resonance reflection. Upon determing that acceptable resonance reflection has been achieved, the material is cured.

Abstract: Flexible ground connectors are adapted to withstand temperature-induced stresses. The connectors may be formed of low thermal conductivity materials. The connectors may be used within a semiconductor package that also encloses a thermoelectric cooling device, a conductive submount, and a semiconductor light source. The submount may be grounded to the package wall by locating a pair of the flexible ground connectors across a gap to a ledge in the wall. The ground connectors may be formed of stainless steel, and they may be gold plated for improved electrical conductivity.

Abstract: A solder bonding system that includes a substrate having a recess and a conductive pad having a width. The conductive pad is disposed in the recess of the substrate. The solder bonding system also includes a solder pad contacting the conductive pad. The solder pad has a width greater than the width of the conductive pad. When the solder pad is heated, it forms a stable solder bond between the conductive pads.

Abstract: An apparatus for passively aligning first and second substrates having micro-components disposed thereon when the substrates do not include patterned surfaces which face each other. The apparatus includes a first depression which cooperates with an alignment sphere to mechanically engage a corresponding depression disposed on the front surface of the first substrate and a second depression which cooperates with a second alignment sphere to mechanically engage a corresponding depression disposed on the front surface of the second substrate. The first and second depression of the alignment apparatus and the alignment spheres cooperate to passively align micro-components disposed on each of the substrates.

Abstract: A method and apparatus for mounting optical elements onto an optical device are described. A mounting structure is produced out of a carrier substrate. The mounting structure includes one or more walls defining a well and surrounding a plurality of protrusions. The well defined by the walls is filled with an adhesive material system, such as epoxy. An optical device is lowered into contact with the epoxy, and then into contact with the protrusions. The displaced epoxy is displaced through one or more conduits into one or more reservoirs. A plurality of such mounting structures enables one to align a plurality of optical elements together in a single plane.

Abstract: A lithography multi-level mask includes a base layer with at least one mesa disposed over the base layer. The mesa has a first transmittance and the substrate has a second transmittance. The first transmittance is greater than or equal to the second transmittance.

Abstract: A method for fabricating an at least one optical fiber array includes planarizing an endface of at least one optical fiber and inserting an endface of the at least one optical fiber in a tool. The at least one optical fiber is then secured in the tool, and at least a portion of the tool is removed exposing the endface of the at least one optical fiber. The resultant product has significant planarity, and enables the endfaces of the optical fiber of the optical fiber arrays to be substantially coplanar.

Abstract: A first waveguide holding member has a first transverse surface region and a first optical waveguide having an end terminating at the first transverse surface region. A second waveguide holding member has a second transverse surface region which confronts the first transverse surface region of the first waveguide holding member and a second optical waveguide having an end terminating at the second transverse surface region. A guide member is operatively coupled to the first and second waveguide holding members and guides the first waveguide holding member in a transverse direction relative to the second waveguide holding member so as to selectively optically couple and decouple the ends of the first and second optical waveguides.