Aspheric Microlens Array for Optical Module Miniaturization
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Solution Overview
Problem
Conventional optical communication modules face challenges in miniaturization and integration due to large beam divergence angles and working distances, leading to significant light loss and reduced performance, especially when the beam path exceeds 140 mm.
Innovation Solution
A microlens array with aspheric-surface shapes on one side, featuring a working distance of 1.30±0.05 mm, curvature radius of 1.1 to 1.5, refractive index of 1.60 to 1.86, and a beam divergence angle of less than 1 mrad, allowing for miniaturization and integration of optical communication modules while maintaining excellent collimating performance across a 1290 nm to 1610 nm wavelength range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a conventional microlens array is used, then the optical communication module can be assembled, but the working distance is large and beam divergence angle is large, preventing miniaturization and causing light loss
Solution Approach 1:
The patent changes the geometric parameters of the microlens array, specifically setting the curvature radius R1 to 1.1-1.5 and working distance WD to 1.30±0.05mm, which reduces the beam divergence angle to less than 1 mrad and enables module miniaturization while maintaining collimating performance
Solution Approach 2:
The patent applies aspheric surface shapes to the microlens array with specific curvature radius parameters (R1=1.1 to 1.5), which improves the collimating performance and reduces beam divergence angle compared to conventional spherical lenses, enabling better miniaturization
2Length of stationary object
If the beam path is extended to 200 mm, then the transmission distance is increased, but light loss increases and performance drops to 60% or less
Solution Approach 1:
By optimizing the microlens array parameters (curvature radius R1=1.1 to 1.5, working distance WD=1.30±0.05mm), the patent achieves a beam divergence angle of less than 1 mrad, which maintains collimating performance above 90% even at 200 mm beam path length, preventing significant light loss
3Volume of moving object
If the working distance is reduced for miniaturization, then the module size is reduced, but achieving low beam divergence angle becomes more difficult
Solution Approach 1:
The patent achieves a working distance of 1.30±0.05mm (minimized for compact size) while simultaneously achieving a beam divergence angle of less than 1 mrad by optimizing the curvature radius parameters (R1=1.1 to 1.5), thus resolving the contradiction between miniaturization and collimating performance
Solution Approach 2:
The aspheric surface design with specific curvature parameters enables the microlens array to achieve excellent collimating performance (beam divergence angle < 1 mrad) at a minimized working distance of 1.30±0.05mm, allowing both miniaturization and high reliability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The proposed microlens array effectively minimizes the working distance and beam divergence angle, enabling 90% or more collimating performance even at a 200 mm beam path, thereby enhancing the miniaturization and integration of optical communication modules with reduced light loss.
Implementation Method 1
a microlens array with a first side thereof having aspheric-surface shapes, wherein a working distance WD is 1.30±0.05 mm, each lens layer has a curvature radius R1 of 1.1 to 1.5, and a beam divergence angle is less than 1 mrad
Data Source
AI summary
A microlens array according to an embodiment of the present disclosure includes lens layers with a first side thereof having aspheric-surface shapes. The microlens array is configured such that an optical communication module may be miniaturized and integrated as a working distance (WD) is minimized to 1.30±0.05 mm, and collimating performance is excellent as a curvature radius (R1) of each lens layer is 1.1 to 1.5.