Capillary Lens Array Monolithic Fusion for Sub-Micron Alignment
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Solution Overview
Problem
The challenge lies in achieving high positional accuracy and reducing variations in lens arrays composed of graded index lenses, particularly when connecting them to other optical components, especially in silicon photonics, where the required accuracy is 0.5 μm or less, and conventional methods lead to increased manufacturing costs and decreased component accuracy due to adhesive use and polishing processes.
Innovation Solution
A capillary-type lens array is created by embedding graded index lenses within an inorganic glass capillary, using heating and drawing technology to fuse the lenses and capillary, eliminating the need for aligning members and adhesives, thereby enhancing mounting accuracy and reducing variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If graded index lenses are arrayed using conventional methods with adhesives and aligning members, then assembly is easier to perform, but positional accuracy deteriorates to several μm level
Solution Approach 1:
The patent merges the graded index lens with the capillary structure by forming the lens directly within the capillary using the same glass material. This integration eliminates the need for separate aligning members and adhesives, achieving both ease of assembly (single-component structure) and high positional accuracy (sub-μm level) through monolithic fabrication.
Solution Approach 2:
The capillary serves as an intermediary structure that both holds and precisely positions the graded index lens. By forming the lens within the capillary during the same manufacturing process, the capillary acts as a built-in aligning member that provides mechanical support and precise positioning simultaneously, eliminating the need for separate alignment components.
2Ease of manufacture
If graded index lenses are arrayed with conventional bonding methods, then manufacturing process is simpler, but component accuracy deteriorates due to adhesive use
Solution Approach 1:
The patent combines the lens formation and capillary formation into a single manufacturing process. The graded index lens is formed by drawing the capillary glass material itself, eliminating the need for separate bonding steps with adhesives. This merged process maintains manufacturing simplicity while achieving high component accuracy through direct monolithic formation.
Solution Approach 2:
The patent extracts and eliminates the adhesive bonding step from the conventional manufacturing process. By forming the lens directly within the capillary using the same glass material, the process removes the intermediate adhesive layer that degrades accuracy, achieving both process efficiency and high precision.
3Adaptability or versatility
If multiple graded index lenses are connected using adhesives, then assembly is more flexible, but positional variation increases reducing product yield
Solution Approach 1:
The patent merges multiple lens-capillary units into a single integrated structure where each lens is formed within its own capillary segment. This monolithic integration eliminates relative positional variations between components that occur with adhesive bonding, while maintaining assembly flexibility through the modular capillary design that can be configured in different arrangements.
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
This approach improves workability and positional accuracy in connecting graded index lenses to other optical components, reduces manufacturing costs, and maintains high component accuracy by integrating lenses and capillaries through a robust, rigid glass structure, ensuring precise alignment and assembly.
Implementation Method 1
by inserting base material having a collimating function into each through hole, and using the same heating and drawing technology as that in capillary production. Therefore, in the capillary-type lens array according to the present disclosure, a plurality of graded index lenses and inorganic glass of the capillary are physically fused.
Data Source
AI summary
A capillary-type lens array having an inorganic glass around a graded index lens, in which a plurality of the graded index lenses and the inorganic glass are physically fused.