Hermetically sealed optical subassembly

• US 6,861,641 B1
• Filed: 03/26/2002
• Issued: 03/01/2005
• Est. Priority Date: 03/26/2002
• Status: Active Grant

• Current Assignee: Optical Communication Products Incorporated (KOCH Industries Incorporated)
• Original Assignee: Optical Communication Products Incorporated (KOCH Industries Incorporated)
• Inventors: Adams, Rich
• Primary Examiner(s): Luu, Thanh X.
• Assistant Examiner(s): Sohn, Seung C.
• Application Number:
  US10/106,710
• Time in Patent Office: 1,071 Days
• Field of Search: 250/239, 385 88- 94, 385/140, 359/362
• US Class Current: 250/239
• CPC Class Codes: G02B 6/421 the intermediate optical component consisting of a short length of fibre, e.g. fibre stub
• CPC Class Codes: G02B 6/4248 Feed-through connections for the hermetical passage of fibres through a package wall see provisionally also G02B6/4428
• CPC Class Codes: G02B 6/4249 comprising arrays of active devices and fibres
• CPC Class Codes: G02B 6/4251 Sealed packages G02B6/4248 takes precedence
• CPC Class Codes: G02B 6/4267 Reduction of thermal stress, e.g. by selecting thermal coefficient of materials
• CPC Class Codes: G02B 6/4292 the light guide being disconnectable from the opto-electronic element, e.g. mutually self aligning arrangements

Abstract

An optical subassembly includes a high speed ceramic substrate having cavity containing an array of photodetectors, and a glass or silicon window for covering the cavity and forming a hermetic seal. A retainer is attached to the window for direct or indirect attachment to a fiber. The hermetic seal protects the device from moisture and other environmental conditions. The window has an index of refraction higher than air that effectively increases the optical pathlength sufficient while maintaining an acceptable coupling efficiency between the optoelectronic device and a fiber. This provides increased spacing within which to place and interconnect components within the cavity on the substrate. In alternate embodiments, the window is decoupled from direct contact with the retainer via a metal frame or ring. Decoupling the window from direct contact with the retainer helps prevent cracking of the window due to mismatches in the coefficients of thermal expansion between the window and the retainer.

Claims

1. An optical subassembly comprising:

a ceramic carrier, the carrier having an U-shaped like structure with two opposing side wall portions that are connected by a flat mounting base portion, the U-shaped like structure forming an open cavity disposed therein, in which an optoelectronic device is mounted on the base and within the cavity;

a lens-less retainer for attachment to one or more optical fibers, wherein the retainer is secured to the carrier for optical alignment of the optoelectronic device and the fiber; and

a window covering the opening in the cavity, and forming a hermetic seal over the optoelectronic device, the window being disposed between the carrier and lens-less retainer and being directly attached to the retainer.

2. The optical subassembly of claim 1, wherein the window comprises silicon.

3. The optical subassembly of claim 1 wherein the window has an index of refraction greater than the index of refraction of air.

4. The optical subassembly of claim 1 wherein the seal meets the requirements of MIL-SPEC 833D.

5. The optical subassembly of claim 1, wherein the optoelectronic device comprises an array of photodetectors.

6. A method for making an optical subassembly comprising:

providing a ceramic carrier, the carrier having an U-shaped like structure with two opposing side wall portions that are connected by a flat mounting base portion, the U-shaped like structure forming an open cavity therein;

mounting at least one optoelectronic device on the base and within the cavity;

metalizing at least a portion of the periphery of a window;

attaching the window to the carrier so that the window extends over the cavity in the carrier and forms a hermetic seal over the optoelectronic device; and

optically coupling an end of at least one optical fiber to the optoelectronic device by directly coupling the window to a lens-less retainer which holds the fiber, wherein the index of refraction of the window increases optical path length between the end of the fiber and the optoelectronic device while maintaining coupling efficiency.

7. The method of claim 6 further comprising actively aligning the at least one optoelectronic device to the end of at least one optical fiber.

8. The method of claim 6 further comprising mounting an array of photodetectors within the opening.

9. An optical transceiver comprising at least one hermetically sealed optical subassembly, the subassembly including:

a ceramic carrier, the carrier having an U-shaped like structure with two opposing side wall portions that are connected by a flat mounting base portion, the U-shaped like structure forming an open cavity disposed therein, in which an optoelectronic device is mounted on the base and within the cavity;

a lens-less retainer for attachment to an optical fiber stub array, wherein the retainer is secured to the carrier for optical alignment of the optoelectronic device and an optical fiber; and

a window covering the opening in the cavity, and forming a hermetic seal over the optoelectronic device, the window being disposed between the carrier and lens-less retainer and being directly attached to the retainer.