Capillary Lens Array NA Conversion via Melt-Drawing

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Solution Overview

Problem

The manufacturing process for arrayed graded index lenses with different numerical apertures (NAs) is complex and difficult to control, leading to low yield and high costs due to the need for precise alignment and assembly of multiple lenses.

Innovation Solution

A capillary type lens array composed of graded index lenses with varying refractive index distribution constants along the optical axis, allowing for NA conversion without requiring a V-groove substrate, using melt-drawing to create arrays with consistent outer shapes and connecting them optically to achieve desired NA values.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple graded index lenses with different NAs are assembled using V-groove substrate and adhesive, then NA conversion function is achieved, but manufacturing complexity increases and yield decreases

Engineering Contradiction:

ImproveNA conversion functionVSAvoidassembly process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges multiple graded index lenses with different NAs into a single integrated optical component. The lenses are arranged in series within a unified structure, eliminating the need for separate V-groove substrates and adhesive bonding. This integration reduces assembly complexity while maintaining the NA conversion function, directly resolving the contradiction between versatility and device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The optical component achieves multi-functionality by incorporating multiple graded index lenses with different numerical apertures within a single device. This allows the component to perform multiple NA conversion functions simultaneously, replacing what would otherwise require multiple separate components and complex assembly procedures, thereby reducing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple graded index lenses are precisely aligned and assembled, then NA conversion is achieved, but manufacturing time increases and cost increases

Engineering Contradiction:

ImproveNA conversion capabilityVSAvoidmanufacturing efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

By combining multiple graded index lenses into a single integrated component manufactured as one unit, the patent eliminates time-consuming alignment and assembly steps. The lenses are positioned and fixed relative to each other during the single manufacturing process, dramatically improving productivity while maintaining NA conversion capability.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If graded index lenses are connected by adhesive or fusion splicing, then NA conversion is achieved, but manufacturing precision control becomes difficult

Engineering Contradiction:

ImproveNA conversion functionVSAvoiddimensional control precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent integrates multiple graded index lenses into a single monolithic structure, eliminating the need for adhesive or fusion splicing connections. This integration ensures precise dimensional control throughout the component, as all lenses are manufactured and positioned with precision during the single manufacturing process, resolving the contradiction between versatility and manufacturing precision.

Inventive Principle:

Principle #5Merging (Combining)

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 simplifies the assembly process, increases yield, and reduces costs by enabling NA conversion in a compact, efficient manner while maintaining high precision.

Implementation Method 1

using melt-drawing to create arrays with consistent outer shapes

Methodology Applied

Scientific EffectMelt-drawing:

Implementation Method 2

melt-drawing a rod of glass

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 3

A graded index lens has a function as an optical lens by continuously changing the refractive index of a glass in the radial direction

Methodology Applied

Scientific EffectRefraction: Refraction

Implementation Method 4

capillary type lens array in which a plurality of graded index lenses is arranged in a capillary

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Data Source

PatentUS11513296B2Optical component, optical connection component with graded index lens, and method of manufacturing optical component

Publication Date: 2022.11.29 NAKAHARA OPTO ELECTRONICS LAB INC

AI summary

An optical component having an NA conversion function which enables arraying without lowering a product yield, with small size and a simple assembly process.There is provided an optical component using a capillary type lens array in which plural graded index lenses each of which is surrounded with glass capillary in all circumferential directions, in which a refractive index distribution constant of the plurality of graded index lenses at one end of the optical component in an optical axis direction of the graded index lens is smaller than a refractive index distribution constant of the plurality of graded index lenses at other end of the optical component in the optical axis direction of the graded index lens.