Patent Application
20250026093
This application claims priority to European patent application EP 23 186 475.2, filed Jul. 19, 2023, the entire content of which is incorporated herein by reference.
The present disclosure is directed to a method for at least partial fabrication of a mirror for an optical cavity and to a fabrication arrangement for at least partial fabrication of a mirror for an optical cavity.
Optical cavities formed by two opposing mirrors are known as tools to enhance the interaction between light and matter by forming an optical resonator. In general, only light with certain wavelengths may pass, enter or transmit the resonator, in which case the light is said to be in resonance with the optical cavity, while other wavelengths are blocked. The spectral separation between wavelengths that may pass the cavity is denoted as free spectral range (FSR) and is mainly determined by a distance between the two opposing mirrors forming the resonator.
For macroscopic cavities, where the mirror separation is large compared to the wavelength of light, the corresponding FSR is relatively small. For microscopic cavities, however, the cavity length approaches the order of magnitude of the wavelength of light and correspondingly the FSR attains larger values. In such scenarios, individual cavity resonances may be singled out by optical filtering techniques. When investigating samples that are introduced into the microscopic cavity, the properties of such individual resonances are of interest. The publication D. Hunger et al.: “A fiber Fabry-Perot cavity with high finesse.” New Journal of Physics 12, 065038 (2010) describes a fiber-based Fabry-Perot micro-cavity with CO2 laser-machined mirrors.
In the publication D. Hunger et al.: “Laser micro-fabrication of concave, low-roughness features in silica”, AIP Advances 2, 012119 (2012), the authors describe a micro-fabrication method to create concave features in silica, either on optical fibers or on flat substrates. The machining uses a single CO2 laser pulse train. Therein, evaporation removes material while a melt layer produces high surface quality. The method allows fabrication of micro-optical devices such as mirror substrates for high-finesse cavities or negative lenses on fiber tips.
For the fabrication of mirrors for microscopic cavities, the removal of material has to take place with a high accuracy, for example of a few nanometers, to be able to create the desired shape of the mirror surface. This places high demands on the stability and reproducibility of the fabrication system.
It is an objective of the present disclosure to provide an improved concept for fabricating mirrors for microscopic cavities at least partially, which increases the achievable accuracy of a surface profile defining the mirror surface.
This objective is achieved by a method and a fabrication arrangement for at least partial fabrication of a mirror for an optical cavity, as described herein.
The disclosure is based on the idea to combine the use of a quantum cascade laser for removing material from a surface to processed of an optical substrate, for example from an end facet of an optical fiber, with a multi-shot sequence when applying the laser radiation.
According to the disclosure, a method for at least partial fabrication of a mirror for an optical cavity, in particular a microscopic optical cavity, is provided. Therein, a surface to be processed of an optical substrate is positioned in an operating plane, which is equal to or parallel to a focal plane of a laser arrangement. A concave surface profile of the surface is generated by applying a sequence of multiple laser shots to the positioned surface by using a quantum cascade laser (QCL) of the laser arrangement.
Here and in the following, light may be understood such that it comprises electromagnetic waves in the visible range, in the infrared range and/or in the ultraviolet range. Accordingly, the expression optical may be understood to be related to light according to this meaning.
The optical substrate is, in particular, suitable for optical purposes. It can, however, also be denoted simply as substrate. The optical substrate is not necessarily transparent or permeable for light. However, in some embodiments, the optical substrate may be permeable at least for light with a wavelength within one or more target wavelength ranges, which may depend on the desired application and/or properties of the optical cavity. For example, the optical substrate may be permeable for light with a wavelength in the range [280 nm, 3000 nm] or within one or more sub-ranges, such as [600 nm, 900 nm], and/or individual wavelengths therein, for example, 780 nm.
The optical substrate being permeable to light of a certain wavelength may be understood such that light of said wavelength may pass through the material of the optical substrate. In particular, the material of the optical substrate may be considered transparent for the light. Obviously, however, the permeability of the material of the optical substrate for the light does not mean that the transmission coefficient for the light is necessarily equal to 100%. Rather, the transmission coefficient depends on the emission wavelength spectrum and the exact choice of the material composition as well geometrical properties of the optical substrate.
The transmission coefficient may for example be understood as an inverse ratio of a light intensity of light entering the material of the optical substrate to the intensity of the light leaving the material of the optical substrate on an opposite side. For example, the optical substrate can be considered permeable for light of a certain wavelength, if the transmission coefficient is 50% or larger, for example 80% or larger, in particular 85% or larger, preferably 90% or larger.
The optical substrate may, in particular, comprise or consist of silicon dioxide, also denoted as silica, or a plastic material. The optical substrate may for example be a flat substrate or plane. For example, flat substrates with a thickness in the range [100 μm, 6 mm] and lateral dimensions in the range [100 μm, 40 mm] may be used.
However, in alternative embodiments, the optical substrate is an optical fiber and the surface to be processed is an end facet of the optical fiber.
The optical fiber may be a single-core fiber comprising exactly one fiber core. In other embodiments, the optical fiber may be a dual-core fiber comprising exactly two fiber cores or a multi-core fiber comprising more than two fiber cores. For example, the fiber core or fiber cores of the optical fiber have a diameter in the range [2 μm, 600 μm] or in the range [4 μm, 120 μm]. For example, the fiber core may be surrounded by a cladding layer. The optical fiber may also be a photonic-crystal fiber in some embodiments.
The laser arrangement comprises, in particular, the QCL and respective optical components for focusing and/or beam shaping and/or filtering the laser light emitted by the QCL. Since, unlike for other types of laser systems, the emission wavelength of a QCL is not strictly tied to the underlying physical process, it can be tuned within certain restrictions. In particular, in the course of the method according to the disclosure, the wavelength of the QCL can be tuned to match specific wavelengths that are particularly suitable for removing material of the optical substrate for example by ablation and/or melt of the material. For example, the wavelength may be tuned such that predetermined absorption maxima of the material to be removed are met or approximately met.
The material to be removed from the optical substrate, in particular the optical fiber, may for example be or comprise silicon dioxide, for which an absorption maximum associated to a vibrational resonance is centered around 9.3 μm. The wavelength can then for example be tuned close to that wavelength, for example from 8 to 11 μm or from 9 to 10 μm. However, in particular for different materials of the optical substrate, also different wavelengths can be used. For tuning or changing the wavelength, different QLCs with different emission wavelength can be used or a QLC with a tunable emission wavelength.
The surface profile to be generated by the method according to the disclosure being concave means that at least a part of the resulting surface lies below other parts of the resulting surface. In particular, the concave surface profile comprises at least one indentation, which may also be denoted as depression or impression, even though it is not generated with applying mechanical pressure. In particular, while certain parts of the surface profile are concave, there may be other parts of the surface profile, which are convex or non-concave.
The multiple laser shots comprise two or more laser shots that may be applied to the same lateral position in the focal plane or to different lateral positions. In general, the multiple laser shots may comprise shots to different positions in in the operating plane, wherein one or more shots are applied to each lateral position. The laser light emitted by the QCL may be pulsed. A shot does not correspond to a single pulse but a shot commonly comprises many pulses.
According to the method for at least partial fabrication of the mirror, the concave surface profile is generated. Depending on the use case and/or the used material of the optical substrate, the processed surface profile, in particular the processed end facet of the optical fiber, may be used as a mirror surface for the optical cavity. In this case, the method can be considered as a method for fabricating the mirror. However, in other cases, further processing of the processed surface, in particular the end facet, and the generated surface profile may be required to achieve the desired optical properties, in particular reflectivity of the mirror. To this end, for example a reflective coating may be applied to the processed surface. In this case, the method according to the disclosure can be considered as a method for partially fabricating the mirror or, in other words, a method for preparing the optical substrate for the fabrication of the mirror.
Combining the application of multiple laser shots with the usage of a QCL has several advantages, in particular compared to a single shot approach and/or to using a CO2-laser for processing the surface. In a single shot approach, a depression is generated by applying a single laser shot to the surface. The resulting depression or indentation typically has an approximately Gaussian shape. This, on the one hand, limits the achievable shapes of the surface profile and, for example, prevents from realizing for example circular or parabolic profiles. Such circular or parabolic or also other types of profiles may, however, be particularly suitable for the application in an optical microscopic cavity. In general, the ability to adapt the actual profile shape to the specific requirements is desirable but not feasible using a single shot approach. Furthermore, the radius or lateral extension of the indentation and the depth of the generated indentations are more or less strictly linked to each other when using a single shot approach. In other words, indentations that are large in lateral direction also have a relatively large depth in longitudinal direction and the other way around for small or shallow indentations. This also leads to non-optimal surface profiles for microscopic optical cavities. These drawbacks are overcome by applying the multiple laser shots at one or more lateral positions.
However, the multi shot approach comes with increased demands regarding the stability and reproducibility of the fabrication arrangement, in particular the laser arrangement. For example, minimal variations, for example in the environmental temperature, may lead to mode jumps in gas lasers like CO2-lasers, which may lead to power variations as well as positional variations in the beam positioning. This prevents a sub-micrometer accuracy in the lateral positioning of the laser shots and therefore reduces the achievable accuracy. Power variations of the emitted laser light are very disadvantageous as well. The material ablation achieved by applying the laser shots is a highly non-linear process. Consequently, only minimal power variations may give rise to significant differences in the result. Consequently, a surface roughness of few nanometers cannot be achieved in this way. These drawbacks are overcome by combining the multi shot approach with the QCL.
Moreover, using the QCL the power absorption by the material to be removed can be concentrated much closer to the surface of the optical substrate, in particular the optical fiber or its end facet, which allows for a much more detailed or accurate removal of the material compared to a CO2-laser.
The QCL is a solid-state laser and can be used with much less overhead compared to the CO2-laser. In particular, there is no need for cooling the QCL, which otherwise could introduce vibrations into the fabrication arrangement affecting reproducibility and stability. Using the QCL also saves space and costs. Furthermore, the QCL can be directly controlled electronically. In addition, since the QCL can be tuned for different wavelengths, the effectivity of the material removal with power absorption can be increased, which leads to an overall reduced optical power to be emitted by the laser. This increases the safety for users.
Furthermore, unlike for a CO2-laser, a QCL does not require specific optics to enable a pulsed operation for material ablation. This reduces the additional effort to set up the laser arrangement correctly and also reduces the portion of laser power that remains unused.
With the method according to the disclosure, due to the combination of QCL with the multi shot approach, a surface roughness of the surface profile in the order of 0.1 nm and an overall accuracy of the dimensions of the surface profile in the order of nanometers is achieved. The flexibility and variability of the achievable surface shapes can be increased allowing also freeform surfaces for more complex and powerful mirror geometries. In particular, hundreds or even thousands of operating points in the operating plane may be used to generate such complex surface structures.
The operating plane may be positioned more or less exactly at the focal plane of the laser arrangement. However, it may also be favorable to offset the operating plane slightly from the focal plane.
According to several embodiments of the method, generating the concave surface profile comprises setting a lateral position of a focal point of the laser arrangement in a sequential manner to a plurality of operating points in the operating plane. For each of the plurality of operating points, at least one of the multiple laser shots is applied to the surface, in particular the end facet of the optical fiber.
In case of a plane substrate, the expression lateral may be understood such as to indicate a direction parallel to the plane substrate, in particular its unprocessed surface. Analogously, in case of an optical fiber, the expression lateral may be understood such as to indicate a direction perpendicular to a longitudinal direction of the optical fiber. In particular, a lateral direction is parallel to the focal plane and the operating plane.
In the first place, the focal point of the laser arrangement is positioned within the focal plane. However, since the operating plane is parallel to the focal plane, this also results in a corresponding positioning in the operating plane. In other words, each operating point in the operating plane is characterized by a corresponding projected operating point in the focal plane, which results from a perpendicular projection of the operating point from the operating plane to the focal plane. Consequently, setting the lateral position to the plurality of operating points in the operating plane may also be understood as setting the lateral position of the focal point in a sequential manner to the plurality of projected operating points in the focal plane.
The plurality of operating points comprises two or more operating points as respective predefined positions. There may also be a predefined order of the plurality of operating points provided and the sequential setting of the lateral position is carried out according to that order. For example, the number of laser shots applied to a given operating point may lie in the range [1, 10]. By applying laser shots to different lateral operating points in the sequential manner, the surface profile can be fabricated in a particularly exact way and/or particularly complex surface profiles may be achieved. By applying more than one laser shot to a single operating point, the optical power of the laser may be reduced and/or the flexibility in the depth profile of the surface may be increased.
According to several exemplary embodiments, the surface to be processed, in particular the end facet, and the laser arrangement are moved laterally with respect to each other to set the lateral position of the focal point in the sequential manner to the plurality of operating points.
In particular, either the laser arrangement remains stationary and the optical fiber is moved laterally or vice versa or a combination of both.
For example, the optical substrate and/or respective components of the laser arrangement may be mounted to respective positioning stages. Such positioning stages are available, in particular for optical fibers, and allow for a very exact placement of the involved components.
Alternatively or in addition, a laser beam of the QCL is deflected by a deflection unit of the laser arrangement to set the lateral position of the focal point in the sequential manner to the plurality of operating points.
Therefore, the effort for ensuring mechanical stability of the positioner stage may be reduced. The deflection arrangement may comprise one or more mirrors that are tiltable, pivotable and/or rotatable. The one or more mirrors may also be implemented as respective micro-electrical-mechanical systems, MEMS.
According to several embodiments, the plurality of operating points comprises at least 10 operating points or at least 30 operating points.
In this way, the achievable complexity and accuracy of the surface profile is increased. In particular, the total number of operating points may lie in the range [10, 2000].
According to several embodiments, the plurality of operating points, in particular all operating points, lies on two or more concentric circles or on two or more concentric ellipses in the operating plane. Alternatively, the plurality of operating points comprises a center point and the remaining of the plurality of operating points lies on two or more concentric circles or on two or more concentric ellipses. The center point lies in the center of the concentric circles or ellipses.
In particular, the predefined order of the operating points may be such that, if applicable, first the center point is set and then one circle or ellipse after another is sampled starting with the innermost circle or ellipse and proceeding in radial direction away from the center. Experiments and tests have revealed that such arrangement and/or ordering of the operating points allow for a particularly accurate and consistent fabrication of the surface profile.
In other embodiments, the predefined order of the operating points may be such that one circle or ellipse after another is sampled starting with the outermost circle or ellipse and proceeding in radial direction towards the center.
According to several embodiments, the concave profile comprises an indentation, in particular an indentation, which is centered in a center of the optical fiber.
According to several embodiments, the concave surface profile comprises two or more indentations, which are arranged according to a predefined geometric figure, in particular a predefined geometric figure in the operating plane.
For example, respective centers of the two or more indentations may be arranged according to the geometric figure. In this way, the optical properties of the mirror and the resulting optical cavity may be tuned in a very flexible manner by choosing the appropriate number and position of the indentations.
For example, the geometric figure may correspond to a polygon and the centers of the respective indentations are located at corner points of the polygon.
A respective radius of curvature at the center of the indentation or indentations may for example lie in the range [5 μm, 1000 μm]. A respective depth of the indentation or indentations may for example range from a few tens of nm to a few micrometers, for example lie in the range [10 nm, 10 μm] or in the range [100 nm, 7 μm].
According to several embodiments, the concave surface profile comprises a bevel surrounding the indentation, in particular in case the optical substrate is the optical fiber and/or surface profile comprises a single indentation in the center of the optical fiber.
In particular, the bevel surrounds the indentation circumferentially and extents from an outer edge or outer boundary of the indentation to an outer edge of the optical fiber.
By providing the bevel, the lateral extension of the processed end facet of the optical fiber can be reduced. In this way, when used as a mirror for a microscopic cavity, the end facet may be positioned closer to a sample and/or may be positioned with increased flexibility.
According to several embodiments, an outer contour of the indentation possess a rotational symmetry, in particular a circular symmetry or a discrete rotational symmetry, for example is circular, when viewed from a direction perpendicular to the operating plane, in particular parallel to the longitudinal direction of the optical fiber, if applicable.
This includes for example deviations from an exact rotational symmetry, which origin from processing tolerances.
According to other embodiments, an outer contour of the indentation is asymmetric, in particular does not possess circular symmetry, for example is elliptic, when viewed from a direction perpendicular to the operating plane, in particular parallel to the longitudinal direction of the optical fiber, if applicable.
Such asymmetric indentation may have particular benefits in specific applications of the mirror in an optical cavity and are enabled by the combination of the multi shot approach and the QCL according to the disclosure.
The disclosure allows to more or less freely choose the intended geometry and accurately reproduce it due to the multi-shot approach in combination with the usage of the QCL.
According to several embodiments, a contour of the indentation in a section plane, which is parallel to a normal axis to the surface in an unprocessed state, in particular parallel to a longitudinal axis of the optical fiber, if applicable, has a circular shape or a parabolic shape ore a Bessel shape or a Gaussian shape or a combination of that shapes. This includes for example deviations from an exact circular, parabolic, Bessel or Gaussian shape, respectively, which origin from processing tolerances.
In exemplary embodiments the shape of the contour in the section plane is circular or parabolic or at least approximately circular or parabolic. The section plane, in particular, comprises the longitudinal axis in case of an optical fiber.
In particular, the circular, parabolic, Bessel and Gaussian shapes can be described by respective mathematical functions. A combination of two or more of such shapes can then for example be described by a convolution of the respective two or more mathematical functions.
According to several embodiments, a further contour of the indentation in a further section plane, which is parallel to the normal axis, in particular to the longitudinal axis of the optical fiber, if applicable, and which is different from the section plane, in particular orthogonal to the section plane, has a circular shape or a parabolic shape or a Bessel shape or a Gaussian shape or a combination of said shapes.
In exemplary embodiments the shape of the contour in the further section plane is circular or parabolic or at least approximately circular or parabolic. The further section plane, in particular, comprises the longitudinal axis in case of an optical fiber.
According to several embodiments, after generating the concave surface profile, the processed surface, in particular the end facet, is coated with a reflective coating.
The reflective coating may for example be a metallic coating, which can for example be applied to the surface profile with sputtering or evaporation. The coating may also comprise a multi-layer stack of two or more different dielectric materials, for example oxides, including for example niobium pentoxide, Nb2O5, silicon dioxide, SiO2, tantalum pentoxide, Ta2O5, hafnium dioxide, HfO2, zirconium dioxide, ZrO2, or aluminum oxide, Al2O3. Depending on the relevant wavelengths, other dielectric materials that can be used include for example indium gallium arsenide, InGaAs, aluminum gallium arsenide, AlGaAs, gallium arsenide, GaAs, aluminum arsenide, AlAs, Pbl-xEuxTe, or europium telluride, EuTe. Also meta surfaces may be used as reflective layers. According to several embodiments, a first material portion of the optical substrate, for example of the optical fiber, in particular of the fiber core, is removed due to laser ablation by applying the sequence of multiple laser shots.
In particular, the wavelength of the light emitted by the QCL is selected or tuned with respect to the material to be removed and/or the optical output power of the QCL is adjusted accordingly such that ablation results. In this way, the material can be removed in a particularly controllable and efficient manner.
According to several embodiments, a second material portion of the optical substrate, for example of the optical fiber, in particular of the fiber core, is melted, in particular melted and not removed, by applying the sequence of multiple laser shots.
In particular, the first material portion is removed and the second material portion is melted and then undergoes a solidification, which leads to a particularly smooth surface and allows to achieve a particularly low surface roughness, even without mechanical polishing steps being necessary. Both effects may happen automatically when applying the sequence of multiple laser shots.
According to a further aspect of the disclosure, a fabrication arrangement for at least partial fabrication of a mirror for an optical cavity is provided. The fabrication arrangement comprises a laser arrangement comprising a quantum cascade laser. The fabrication arrangement comprises a positioner device with a holder for taking up an optical substrate, for example an optical fiber, which is configured to move the optical substrate relative to the laser arrangement. The fabrication arrangement comprises at least one control unit, which is configured to control the positioner device to position a surface to be processed of the optical substrate, in particular an end facet of the optical fiber, in an operating plane, which is equal to or parallel to a focal plane of the laser arrangement, in particular by moving the optical substrate relative to the laser arrangement. The at least one control unit is configured to control the quantum cascade laser to apply a sequence of multiple laser shots to the surface, in particular the end facet to generate a concave surface profile of the surface in particular the end facet.
The holder may for example be a fiber holder for taking up the optical fiber. The positioner device may, in some embodiments, be configured to move the optical substrate and thereby the surface to be processed laterally with respect to the stationary laser arrangement to set the lateral position of the focal point in a sequential manner to a plurality of operating points in the operating plane. Alternatively, the fabrication arrangement may comprise a further positioner device, which is configured to carry the quantum cascade laser and is configured to move the quantum cascade laser with respect to the optical substrate to set the lateral position of the focal point in the sequential manner to the plurality of operating points.
In some embodiments, the fabrication arrangement comprises a deflection unit, which is arranged and configured to deflect a laser beam of the quantum cascade laser to set the lateral position of the focal point in the sequential manner to the plurality of operating points.
In particular, the at least one control unit stores an operation protocol, which defines the respective positions of the plurality of operating points and the number of shots to be applied to each of the operating points et cetera.
The at least one control unit may comprise or consist of at least one computing unit. A computing unit may in particular be understood as a data processing device, which comprises processing circuitry. The computing unit can therefore in particular process data to perform computing operations. This may also include operations to perform indexed accesses to a data structure, for example a look-up table, LUT.
In particular, the computing unit may include one or more computers, one or more microcontrollers, and/or one or more integrated circuits, for example, one or more application-specific integrated circuits, ASIC, one or more field-programmable gate arrays, FPGA, and/or one or more systems on a chip, SoC. The computing unit may also include one or more processors, for example one or more microprocessors, one or more central processing units, CPU, one or more graphics processing units, GPU, and/or one or more signal processors, in particular one or more digital signal processors, DSP. The computing unit may also include a physical or a virtual cluster of computers or other of said units.
In various embodiments, the computing unit includes one or more hardware and/or software interfaces and/or one or more memory units.
A memory unit may be implemented as a volatile data memory, for example a dynamic random access memory, DRAM, or a static random access memory, SRAM, or as a non-volatile data memory, for example a read-only memory, ROM, a programmable read-only memory, PROM, an erasable programmable read-only memory, EPROM, an electrically erasable programmable read-only memory, EEPROM, a flash memory or flash EEPROM, a ferroelectric random access memory, FRAM, a magnetoresistive random access memory, MRAM, or a phase-change random access memory, PCRAM.
The disclosure will now be described with reference to the drawings wherein:
The fabrication arrangement 10 comprises a laser arrangement 2, which contains a quantum cascade laser (QCL) 6. The fabrication arrangement 10 further comprises a positioner device 3 with a fiber holder 34 for taking up the optical fiber 1 and, for example, further optical fibers 1′. The positioner device 3 is configured to move the optical fiber 1 relative to the laser arrangement 2.
In some exemplary embodiments, the positioner device 3 comprises a base portion 4, which may remain stationary and a slider 5 carrying the fiber holder 34. The slider 5 is for example movable in three directions X, Y, Z in order to position the optical fiber 1 relative to the laser arrangement 2. To this end, at least one control unit (not shown) of the fabrication arrangement 10 is configured to control the positioner device 3 to position an end facet 13 (see
As indicated in
In particular, the fabrication arrangement 10 is configured to carry out a method for at least partial fabrication of a mirror for an optical cavity 16 from an optical fiber according to the disclosure. A schematic method flow is shown in
According to step 200, the end facet 13 is positioned in the operating plane 35. According to step 210, the sequence of multiple laser shots is applied to the end facet by using the QCL 6. According to some embodiments, the lateral position of a focal point of the laser arrangement 2 is set in a sequential manner to a plurality of operating points 30 (see
The positioner device 3 may be configured to place the slider 5 such that the end facet of the optical fiber 1 is placed in a focal plane or focal point of the Mirau objective 27. Consequently, the image taken by the camera 27 may be used to control the fabrication process. Also, adaptive methods could be used, wherein applying sequences of multiple laser shots and control of the fabrication process, for example with the white light interferometer 23, are carried out in an alternating manner. Machine learning based approaches using the images would also be conceivable.
In the example of
| Number | Date | Country | Kind |
|---|---|---|---|
| 23 186 475.2 | Jul 2023 | EP | regional |
