Optical fiber collimator manufacturing method and optical fiber collimator

Abstract

The invention provides an optical fiber collimator manufacturing method and an optical fiber collimator, and relates to the technical field of optical signal transmission. The manufacturing method of the optical fiber collimator comprises the following steps: processing lenses and optical fiber grooves which are arranged in an array on a substrate, and processing a plurality of glue filling holes on the substrate; respectively inserting a plurality of optical fibers into the plurality of optical fiber grooves; optical cement is filled in the plurality of glue filling holes; the insertion depth of at least part of the optical fibers is adjusted, so that output light of a channel corresponding to each optical fiber groove is collimated light; the manufacturing method of the optical fiber collimator can guarantee the yield and reliability of the optical fiber collimator.

Description

Technical Field

[0001] This application relates to the field of optical signal transmission technology, and more specifically, to a method for manufacturing an optical fiber collimator and an optical fiber collimator. Background Technology

[0002] Fiber optic collimators are a commonly used device in various optical systems. With the rapid development of AI technology, data centers have an increasing demand for the bandwidth of switches. The traditional optical-electrical-optical signal transmission links of switches have gradually revealed their shortcomings such as low bandwidth, high upgrade frequency, and high power consumption. Therefore, optical switches that can directly transmit optical signals are gradually replacing traditional switches.

[0003] As a core component of optical switches, fiber optic collimators mainly consist of perforated plates, fiber arrays, and collimating lens arrays. Currently, there are inevitably focal length differences between the lenses in the collimating lens array. When coupling the fiber array and the lens array, it is impossible to couple all the lenses to the optimal degree, which will lead to a decrease in the final yield of the fiber optic collimator. Summary of the Invention

[0004] The purpose of this application includes, for example, providing a method for manufacturing an optical fiber collimator that can ensure the yield and reliability of the optical fiber collimator.

[0005] The purpose of this application also includes providing an optical fiber collimator with high yield and reliability.

[0006] The embodiments of this application can be implemented as follows: In a first aspect, embodiments of this application provide a method for manufacturing an optical fiber collimator, comprising: Lenses and fiber optic channels arranged in an array are fabricated on the substrate, and multiple potting holes are fabricated on the substrate. Multiple optical fibers are inserted into multiple optical fiber slots respectively; Fill the plurality of potting holes with optical adhesive; The insertion depth of at least some of the optical fibers is adjusted so that the output light of each channel corresponding to each optical fiber slot is collimated light; The fiber optic slot is opened in a first direction, and the glue-filling hole is opened in a second direction perpendicular to the first direction. Each glue-filling hole is simultaneously connected to multiple fiber optic slots arranged along the second direction.

[0007] Optionally, the steps of fabricating an array of lenses and fiber optic channels on the substrate, and fabricating multiple potting holes on the substrate, include: The fiber groove and the potting hole are fabricated on the substrate using a femtosecond laser.

[0008] Optionally, the step of inserting multiple optical fibers into multiple optical fiber slots includes: One end of the optical fiber is inserted into the corresponding potting hole through the optical fiber slot.

[0009] Optionally, the step of filling the plurality of potting holes with optical adhesive includes: Place the vacuum nozzle and the glue tray containing the optical adhesive at opposite ends of the glue-filling hole; Open the vacuum nozzle to draw in the optical adhesive from the adhesive tray and fill the dispensing hole.

[0010] Optionally, in the step of placing the vacuum nozzle and the adhesive tray containing optical adhesive at both ends of the dispensing hole, the vacuum nozzle and the adhesive tray are respectively disposed at the top and bottom of the substrate.

[0011] Optionally, after adjusting the insertion depth of at least a portion of the optical fibers to ensure that the output light of each channel corresponding to a fiber slot is collimated, the method further includes: The substrate is irradiated with ultraviolet light to cure the optical adhesive.

[0012] Optionally, the substrate includes a first substrate and a second substrate, and the fiber collimator manufacturing method includes: Lenses arranged in an array are fabricated on the first substrate, and fiber optic channels arranged in an array are fabricated on the second substrate. The first substrate and the second substrate are then bonded together.

[0013] Secondly, this application also provides an optical fiber collimator manufactured using the aforementioned optical fiber collimator manufacturing method.

[0014] Optionally, the potting hole is a square hole or a rectangular hole.

[0015] Optionally, the lens is a silicon lens, a glass-molded lens, or a polymer lens.

[0016] The beneficial effects of the fiber optic collimator manufacturing method and the fiber optic collimator provided in this application embodiment include, for example, in the fiber optic collimator manufacturing method, firstly, lenses and fiber slots arranged in an array are processed on a substrate, and multiple potting holes are processed on the substrate. Then, multiple optical fibers are inserted into multiple fiber slots respectively, and optical glue is filled into multiple potting holes. Then, the insertion depth of at least some of the optical fibers is adjusted so that the output light of each fiber slot corresponding to the channel is collimated light. This compensates for the differences in optical performance caused by manufacturing tolerances in the focal length or radius of curvature of each lens in the lens array, and achieves output consistency between channels, which helps to improve the overall yield and reliability of the fiber optic collimator. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a flowchart of steps S1-S5 in the fiber optic collimator manufacturing method; Figure 2 This is a schematic diagram of the first type of fiber optic collimator; Figure 3 This is a cross-sectional view of the first type of fiber optic collimator; Figure 4 This is a schematic diagram illustrating the injection of optical adhesive into the glue-filling hole; Figure 5 This is an exploded view of the second type of fiber optic collimator; Figure 6 This is a schematic diagram of the second substrate. Figure 7 This is a cross-sectional view of the second substrate.

[0019] Icons: 100-substrate; 110-lens; 120-fiber optic channel; 130-potting hole; 140-first substrate; 150-second substrate; 200-fiber optic cable; 300-vacuum nozzle; 400-reel tray. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0021] Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0022] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0023] In the description of this application, it should be noted that if terms such as "upper," "lower," "inner," or "outer" are used to indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product of the invention is usually placed during use, they are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0024] Furthermore, the terms "first" and "second" are used only to distinguish descriptions and should not be interpreted as indicating or implying relative importance.

[0025] It should be noted that, where there is no conflict, the features in the embodiments of this application can be combined with each other.

[0026] Please refer to Figures 1-4 This application provides a method for manufacturing an optical fiber collimator, comprising: Step S1: A lens 110 and an optical fiber groove 120 arranged in an array are fabricated on the substrate 100, and a plurality of potting holes 130 are fabricated on the substrate 100.

[0027] Step S2: Insert multiple optical fibers 200 into multiple optical fiber slots 120 respectively.

[0028] Step S3: Fill the multiple potting holes 130 with optical adhesive.

[0029] Step S4: Adjust the insertion depth of at least some of the optical fibers 200 so that the output light of each channel corresponding to each optical fiber slot 120 is collimated light.

[0030] The fiber optic slot 120 is opened in a first direction, and the glue-filling hole 130 is opened in a second direction perpendicular to the first direction. A single glue-filling hole 130 is simultaneously connected to multiple fiber optic slots 120 arranged along the second direction.

[0031] In the above steps, firstly, lenses 110 and fiber optic channels 120 arranged in an array are fabricated on the substrate 100, and multiple potting holes 130 are also fabricated. The substrate 100 can be an integral structure made of a single glass material, or it can be a composite structure formed by bonding multiple layers of substrates 100 together. The lenses 110 are used to collimate the diverging light emitted from the end face of the fiber optic cable 200, and the fiber optic channels 120 are used to accommodate and position the fiber optic cable 200 so that its optical axis is aligned with the optical axis of the corresponding lens 110.

[0032] The fiber optic groove 120 is defined by a first direction, which can be a direction perpendicular to the large surface of the substrate 100. The potting hole 130 is defined by a second direction, which is perpendicular to the first direction and can be vertically penetrating the substrate 100, forming a spatial layout that intersects and connects with the fiber optic groove 120. A single potting hole 130 can simultaneously connect with multiple fiber optic grooves 120 arranged along the second direction. That is, a vertically arranged potting hole 130 can span multiple fiber optic grooves 120, thereby realizing a structural design in which multiple channels share a single potting path. This connection allows optical adhesive to enter from the potting hole 130 and contact multiple optical fibers 200, filling the gaps between them.

[0033] After the fiber optic slots 120 are fabricated, multiple optical fibers 200 are inserted into their respective slots 120, with one end of each fiber 200 reaching the area of ​​the potting hole 130. Subsequently, optical adhesive is filled into the potting holes 130, gradually filling the gaps between the optical fibers 200 and the fiber optic slots 120. Because the potting holes 130 are arranged along the second direction and connected to the multiple fiber optic slots 120, adhesive supply to multiple channels can be completed in a single operation, improving production efficiency.

[0034] The purpose of adjusting the insertion depth of fiber optic cable 200 is to compensate for the differences in optical performance caused by manufacturing tolerances in the curvature radii of curvature of each lens 110 in the lens 110 array. By fine-tuning the insertion depth of each fiber optic cable 200 in its corresponding fiber slot 120, the position of the end face of the fiber optic cable 200 relative to the focal point of the lens 110 can be changed, thereby achieving collimation of the beam output from the corresponding channel of each fiber slot 120. For example, if the curvature radius of curvature of a lens 110 in a certain channel is too small or the fiber optic cable 200 is inserted too shallowly, the output light may exhibit converging characteristics; conversely, it may output diverging light. Only when the fiber optic cable 200 is in the appropriate position can ideal collimated output be achieved. Therefore, the process of adjusting the insertion depth of fiber optic cable 200 achieves output consistency between channels, which helps to improve the overall yield and reliability of the fiber optic collimator.

[0035] Step S1 includes: using a femtosecond laser to process fiber grooves 120 and potting holes 130 on substrate 100.

[0036] In this step, a femtosecond laser is used to process the fiber optic groove 120 and the potting hole 130 on the substrate 100. It should be noted that a femtosecond laser is an ultrashort pulse laser with extremely high spatial resolution and nonlinear absorption characteristics, enabling precision micromachining within transparent materials such as glass without causing thermal damage to the surrounding area. Specifically, by controlling the position of the laser focus, point-by-point ablation can be performed within the substrate 100 to form a three-dimensional structure, thereby processing the fiber optic groove 120 and the potting hole 130. Of course, other laser processing methods can be used in other embodiments, and this is not limited.

[0037] During processing, fiber optic grooves 120 are formed along a first direction to accommodate the optical fiber 200 and maintain its stable position; potting holes 130 are processed along a second direction perpendicular to it, intersecting and communicating with multiple fiber optic grooves 120 to form a glue transfer channel. Because femtosecond lasers can precisely control the processing depth and shape, it ensures that the fiber optic grooves 120 do not completely penetrate the substrate 100, but terminate at an appropriate position, while precisely forming potting holes 130 for guiding the glue. The use of femtosecond laser processing improves structural accuracy and assembly consistency, providing a reliable guarantee for subsequent glue injection and alignment of the optical fiber 200.

[0038] Step S2 includes inserting one end of the optical fiber 200 into the corresponding potting hole 130 through the optical fiber groove 120.

[0039] This step clarifies that one end of the optical fiber 200 needs to be extended into the corresponding potting hole 130. Specifically, during the assembly process, the optical fiber 200 enters the optical fiber groove 120 from one side of the substrate 100 along the first direction and continues to extend forward until its end extends into the potting hole 130 that communicates with the optical fiber groove 120. At this point, the potting hole 130 provides a space to accommodate the end of the optical fiber 200.

[0040] It should be noted that the optical fiber 200 does not need to completely penetrate the entire substrate 100, but terminates at the location of the potting hole 130. This arrangement allows for axial fine-tuning of the optical fiber 200 before the adhesive cures, in order to match the differences in the actual radii of curvature of different lenses 110. Simultaneously, since the potting hole 130 is filled with optical adhesive, after the end of the optical fiber 200 is inserted into it, the adhesive can fully coat the outer wall of the optical fiber 200 and form a stable bonding interface within the potting hole 130, thereby improving mechanical strength and optical compatibility.

[0041] Step S3 includes: Sub-step S31: Place the vacuum nozzle 300 and the glue tray 400 containing optical glue at both ends of the glue dispensing hole 130, respectively.

[0042] Sub-step S32: Open the vacuum nozzle 300 to draw in the optical adhesive in the adhesive tray 400 and fill the dispensing hole 130.

[0043] In practice, the above steps involve placing the vacuum nozzle 300 and the adhesive tray 400 containing optical adhesive at opposite ends of the dispensing hole 130. The adhesive tray 400 is positioned on one side of the dispensing hole 130 to provide the adhesive source, while the vacuum nozzle 300 is positioned on the opposite side to apply negative pressure. When the vacuum nozzle 300 is activated, the resulting suction action gradually draws the optical adhesive from the adhesive tray 400 into the dispensing hole 130, propelling the adhesive flow in the second direction.

[0044] Since the potting hole 130 is connected to multiple fiber slots 120 arranged along the second direction, the adhesive fills the gap between the potting hole 130 and the fiber 200 at the same time as filling the potting hole 130. Compared with the traditional method of using a syringe for dispensing, this method uses the negative pressure of the vacuum nozzle 300 to drive the adhesive to fill the potting hole 130 more smoothly and continuously.

[0045] In sub-step S31, the vacuum nozzle 300 and the adhesive tray 400 are respectively disposed on the top and bottom of the substrate 100.

[0046] This step specifies that the vacuum nozzle 300 and the adhesive tray 400 are respectively set at the top and bottom of the substrate 100. The adhesive tray 400 is placed on the bottom side of the substrate 100 and the vacuum nozzle 300 is placed on the opposite side at the top, so that the optical adhesive enters the potting hole 130 from the bottom of the substrate 100 and flows upward under the traction of the vacuum negative pressure, realizing the bottom-to-top filling process.

[0047] In practice, the vertical pressure gradient helps the adhesive overcome gravity and interfacial tension, allowing it to be smoothly injected into and fill the potting hole 130. Since one end of the optical fiber 200 is already inserted into the potting hole 130, this filling method ensures that the adhesive fully coats the outer wall of the optical fiber 200, forming a complete bonding interface and improving mechanical stability and optical compatibility. Simultaneously, the bottom-up injection path facilitates the removal of air from the potting hole 130, reducing the risk of air bubble retention and improving encapsulation reliability.

[0048] After step S4, the following also includes: Step S5: Irradiate the substrate 100 with an ultraviolet light device to cure the optical adhesive.

[0049] After adjusting the insertion depth of the optical fiber 200, the substrate 100 needs to be irradiated with ultraviolet light to cure the optical adhesive. Specifically, after the position of each optical fiber 200 is adjusted so that the output light of the corresponding channel is collimated, the devices need to be fixed relatively. The optical adhesive, as the medium connecting the optical fiber 200 and the substrate 100, needs to change from a flowing state to a cured state to lock the final position of the optical fiber 200.

[0050] It should be noted that irradiating the substrate 100 with ultraviolet light can trigger a photopolymerization reaction in the optical adhesive, thereby rapidly completing the curing process. Ultraviolet irradiation offers advantages such as short reaction time, controllable energy, and minimal thermal impact on the substrate 100, making it suitable for mass production of high-precision optical devices. The cured adhesive stably maintains the mechanical connection between the optical fiber 200 and the potting hole 130, ensuring optical path stability during long-term use.

[0051] Please combine Figures 5-7 In an optional embodiment, substrate 100 includes a first substrate 140 and a second substrate 150, and the fiber optic collimator manufacturing method includes: Lenses 110 arranged in an array are fabricated on the first substrate 140, and fiber optic channels 120 arranged in an array are fabricated on the second substrate 150. The first substrate 140 and the second substrate 150 are then bonded together.

[0052] This step provides an optional substrate 100 forming method, in which the substrate 100 is divided into two independent components: a first substrate 140 and a second substrate 150, and different functional structures are processed on each component. Specifically, an array of lenses 110 is processed on the first substrate 140 for collimating the light beam emitted from the end face of the optical fiber 200; while an array of fiber grooves 120 is processed on the second substrate 150 for accommodating and positioning multiple optical fibers 200. After the precision processing of the structures of the first substrate 140 and the second substrate 150 is completed, the first substrate 140 and the second substrate 150 are connected together by an adhesive process to form a complete substrate 100 structure.

[0053] In this embodiment, the first substrate 140 can be made of a material suitable for forming the optical lens 110, such as a glass molding substrate 100 or a silicon-based material, to facilitate the formation of a high-precision microlens 110 array through hot pressing or etching processes; while the second substrate 150 is typically made of transparent glass material, which facilitates the internal processing of structures such as non-through fiber optic channels 120 and through-hole potting holes 130 using femtosecond lasers. Since the functions of the first substrate 140 and the second substrate 150 are clearly defined, their respective processing parameters can be optimized independently, improving the manufacturing flexibility of the overall structure.

[0054] In the actual assembly process, the optical fiber 200 is first inserted into the optical fiber slot 120 of the second substrate 150, and optical adhesive is injected through the potting hole 130. Then, the first substrate 140 with the integrated lens 110 is aligned and bonded to it. At this time, the optical axis of each lens 110 must be aligned with the end face of the optical fiber 200 in the corresponding optical fiber slot 120 to ensure optical path matching. During the bonding process of the first substrate 140 and the second substrate 150, UV-curable adhesive or other optical adhesives can be used, and appropriate pressure should be applied and the curing conditions controlled to reduce deformation.

[0055] An embodiment of this application also provides an optical fiber collimator, manufactured using the aforementioned optical fiber collimator manufacturing method. The manufactured optical fiber collimator includes a substrate 100 and multiple optical fibers 200. The multiple optical fibers 200 are inserted one-to-one into multiple optical fiber slots 120, and the ends of each optical fiber 200 extend into corresponding potting holes 130. The optical adhesive cured within the potting holes 130 locks the position of the optical fibers 200, ensuring that the output light from each channel is collimated. Overall, the technical effect of this optical fiber collimator is essentially the same as that of the optical fiber collimator manufacturing method, and will not be elaborated further.

[0056] In an optional embodiment, the potting hole 130 is a square hole or a rectangular hole; the lens 110 is a silicon lens, a glass molded lens, or a polymer lens.

[0057] The square or rectangular potting hole 130 facilitates the formation of a regular adhesive interface during the potting process. Specifically, because the inner wall of the square or rectangular cross-section has a well-defined boundary and smooth sidewalls, a planar contact interface can be formed between the adhesive and the inner wall of the potting hole 130 after the optical adhesive is filled, reducing light scattering caused by curved surfaces. Furthermore, this type of hole can be precisely controlled via femtosecond laser processing to ensure dimensional consistency.

[0058] In addition, the glue-filling hole 130, as a vertically arranged channel, is connected to multiple fiber optic slots 120 arranged horizontally. When using a bottom-up vacuum suction glue-filling process, the regular channel structure of the glue-filling hole 130 is conducive to the smooth flow of glue and further improves the filling integrity.

[0059] Lens 110 can be selected as a silicon lens, a glass-molded lens, or a polymer lens, indicating that this fiber optic collimator supports the integration of microlenses using multiple material systems. Silicon lenses are suitable for infrared applications, possessing good thermal stability and high refractive index characteristics; glass-molded lenses have excellent optical transmittance and surface precision, making them suitable for mass production; while polymer lenses are lower in cost, more flexible in processing, and can be used in scenarios with moderate performance requirements.

[0060] In summary, this application provides a method for manufacturing an optical fiber collimator and an optical fiber collimator. In this manufacturing method, lenses 110 and optical fiber slots 120 arranged in an array are first processed on a substrate 100, and multiple potting holes 130 are processed on the substrate 100. Then, multiple optical fibers 200 are inserted into the multiple optical fiber slots 120 respectively, and optical adhesive is filled into the multiple potting holes 130. Then, the insertion depth of at least some of the optical fibers 200 is adjusted. Finally, the substrate 100 is irradiated with an ultraviolet device to cure the optical adhesive and lock the final position of the optical fibers 200, so that the beam output from the corresponding channel of each optical fiber slot 120 reaches the collimation state, ensuring the yield and reliability of the optical fiber collimator.

[0061] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A method of manufacturing a fiber collimator, characterized by, The application relates to a fiber collimator manufacturing method. The method comprises the following steps: processing lenses (110) and fiber grooves (120) in an array on a substrate (100), and processing a plurality of glue filling holes (130) on the substrate (100); a plurality of optical fibers (200) are respectively inserted into the plurality of fiber grooves (120); optical glue is filled into the plurality of glue filling holes (130); the insertion depth of at least part of the optical fibers (200) is adjusted, so that the output light of each corresponding channel of the fiber groove (120) is collimated light; wherein the opening direction of the fiber groove (120) is a first direction, the opening direction of the glue filling hole (130) is a second direction perpendicular to the first direction, and a single glue filling hole (130) is simultaneously connected with a plurality of fiber grooves (120) arranged along the second direction.

2. The method of claim 1, wherein The step of processing lenses (110) and fiber grooves (120) in an array on a substrate (100), and processing a plurality of glue filling holes (130) on the substrate (100) comprises the following steps: femtosecond laser is used to process the fiber grooves (120) and the glue filling holes (130) on the substrate (100).

3. The method of claim 1, wherein The step of inserting a plurality of optical fibers (200) into a plurality of fiber grooves (120) comprises the following steps: one end of the optical fiber (200) is inserted into the corresponding glue filling hole (130) through the fiber groove (120).

4. The method of claim 1, wherein The step of filling optical glue into a plurality of glue filling holes (130) comprises the following steps: a vacuum suction nozzle (300) and a glue disc (400) containing optical glue are respectively placed at two ends of the glue filling hole (130); the vacuum suction nozzle (300) is turned on to suck the optical glue in the glue disc (400) and fill the glue filling hole (130).

5. The method of claim 4, wherein In the step of placing the vacuum suction nozzle (300) and the glue disc (400) containing optical glue at two ends of the glue filling hole (130), the vacuum suction nozzle (300) and the glue disc (400) are respectively arranged on the top and bottom of the substrate (100).

6. The method of claim 1, wherein After the step of adjusting the insertion depth of at least part of the optical fibers (200) so that the output light of each corresponding channel of the fiber groove (120) is collimated light, the method further comprises the following steps: ultraviolet equipment is used to irradiate the substrate (100) to cure the optical glue.

7. The method of claim 1, wherein The substrate (100) comprises a first substrate (140) and a second substrate (150), and the fiber collimator manufacturing method comprises the following steps: lenses (110) are processed in an array on the first substrate (140), fiber grooves (120) are processed in an array on the second substrate (150), and the first substrate (140) and the second substrate (150) are bonded.

8. An optical fiber collimator characterized by, The fiber collimator manufacturing method is manufactured by any one of claims 1-7.

9. The fiber collimator of claim 8, wherein, The glue filling hole (130) is a square hole or a rectangular hole.

10. The fiber collimator of claim 8, wherein, The lens (110) is a silicon lens, a glass mold pressing lens or a polymer lens.

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