Cylindrical Lens Optical Fiber Coupling Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for optically coupling photonic components with optical fibers are costly and have low yield due to the need for precise alignment of custom lens arrays, which increases manufacturing complexity and costs.
Innovation Solution
The use of multiple cylindrical lenses, where one lens expands optical signals along a predefined dimension and another lens optically couples with it to condense the signals, eliminating the need for a separate lens array and allowing for passive optical alignment, thereby reducing manufacturing costs and improving alignment tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a custom lens array is used to achieve suitable optical coupling efficiency, then optical coupling efficiency is improved, but manufacturing precision requirements increase and manufacturing complexity increases
Solution Approach 1:
The patent divides the optical coupling function into two separate cylindrical lens elements instead of using a single custom lens array. Each cylindrical lens performs a specific function (one focuses in the horizontal plane, the other in the vertical plane), thereby segmenting the complex alignment problem into simpler, independent alignment steps that are easier to manufacture and assemble.
Solution Approach 2:
The patent embeds the two cylindrical lens elements within the existing optical fiber and photonic component structures. The lenses are positioned between the optical fiber array and the photonic component, nesting the lens function within the existing assembly rather than requiring separate custom lens array integration.
2Reliability
If a custom lens array is used to achieve suitable optical coupling efficiency, then optical coupling efficiency is improved, but device complexity increases
Solution Approach 1:
The cylindrical lens elements serve multiple functions: they focus light in specific planes, simplify alignment procedures, and can be manufactured using standard techniques. By using off-the-shelf cylindrical lenses rather than custom-designed lens arrays, the patent achieves universal applicability across different optical coupling applications while reducing device complexity.
Solution Approach 2:
Instead of using a complex lens array to focus light, the patent inverts the approach by using simple cylindrical lenses that create line focuses. This inversion of the traditional lens array concept simplifies the optical system while maintaining coupling efficiency.
3Reliability
If precise alignment is performed along multiple axes to achieve suitable optical coupling efficiency, then optical coupling efficiency is improved, but productivity decreases
Solution Approach 1:
By segmenting the focusing function into two separate cylindrical lenses with orthogonal orientations, the patent reduces the dimensional alignment requirements for each lens. Each lens only needs to be aligned in one primary direction rather than requiring precise multi-axis alignment, thereby speeding up the assembly process and improving productivity.
4Reliability
If a custom lens array is used to achieve suitable optical coupling efficiency, then optical coupling efficiency is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive custom-made lens arrays with inexpensive, commercially available cylindrical lenses. These standard components can be purchased off-the-shelf and do not require costly custom manufacturing processes, thereby significantly reducing the overall manufacturing cost of the optical coupling assembly.
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 enables a low-cost, high-yield method for optically coupling optical fibers to photonic components, achieving alignment tolerances comparable to active lens alignment techniques while reducing manufacturing costs and eliminating the need for custom lens arrays.
Implementation Method 1
at least a first cylindrical lens element fixedly connected with the one or more optical fibers and configured to expand the one or more optical signals along a predefined dimension
Implementation Method 2
at least a second cylindrical lens element optically coupled with the first cylindrical lens element and configured to condense the expanded one or more optical signals along the predefined dimension
Data Source
AI summary
A system and related method and assembly are disclosed. The system comprises one or more optical fibers configured to propagate one or more optical signals. The system further comprises at least a first cylindrical lens element fixedly connected with the one or more optical fibers and configured to expand the one or more optical signals along a predefined dimension. The system further comprises at least a second cylindrical lens element optically coupled with the first cylindrical lens element and configured to condense the expanded one or more optical signals along the predefined dimension.