Preferentially-Etchable Optical Fiber Batch Manufacturing

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Solution Overview

Problem

Current laser micromachining techniques for optical fibers are limited by the complexity of geometry produced and require individual alignment, making them time-consuming and costly for manufacturing optical devices.

Innovation Solution

A method involving a structure-forming fiber with a preferentially-etchable portion and radial and axial etching boundaries, allowing for batch processing and precise control over etching to create complex optical structures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If laser micromachining is used to machine optical fibers individually, then precision lens shapes and diffraction gratings can be formed, but the process becomes time-consuming and limits productivity

Engineering Contradiction:

Improveprecision lens shapeVSAvoidproduction speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The optical fiber is segmented into multiple regions with different etching rates (preferentially-etchable portion vs. non-etchable portion). This segmentation allows the fiber to be processed in batches while maintaining precise geometric control, as each segment etches at a controlled rate to form the desired lens shape without requiring individual alignment of each fiber.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the material parameter of the fiber by creating regions with different etching rates through controlled doping or composition variation. This parameter change enables selective etching during batch processing, allowing multiple fibers to be processed simultaneously with precise geometric outcomes, thereby improving productivity while maintaining manufacturing precision.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If individual fiber positioning and alignment is performed before laser processing, then precise microstructure geometry can be achieved, but the process becomes complex and costly

Engineering Contradiction:

Improvemicrostructure geometryVSAvoidalignment process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The fiber structure itself provides the alignment and positioning functionality through its inherent geometry and the preferentially-etchable portions that self-align during batch etching. The preferentially-etchable portions act as self-positioning features that automatically align during the etching process, eliminating the need for complex external alignment mechanisms and reducing device complexity.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The fiber is pre-formed with preferentially-etchable portions and non-etchable portions during manufacturing, before the actual micromachining process. This preliminary structuring of the fiber with built-in alignment features eliminates the need for complex alignment procedures during processing, as the geometry is already predetermined in the fiber structure itself.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If laser micromachining is used for optical fiber processing, then specific microstructures can be formed, but the geometry of formed microstructure is limited

Engineering Contradiction:

Improvemicrostructure formationVSAvoidmicrostructure geometry variety

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The optical fiber is created with local quality variations, including preferentially-etchable portions with specific refractive indices and non-etchable portions. This local quality differentiation enables the formation of diverse microstructure geometries (lens shapes, diffraction gratings, waveguide structures) by controlling where etching occurs and at what rate, significantly increasing geometric versatility while maintaining manufacturing precision.

Inventive Principle:

Principle #3Local quality

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

Enables rapid and cost-effective production of complex optical structures with precise dimensions, suitable for mass production and improving productivity in optical device manufacturing.

Implementation Method 1

etching the preferentially-etchable portion to at least one radial etching boundary and at least one axial etching boundaries

Methodology Applied

Scientific EffectChemical etching:

Data Source

PatentUS8557129B2Methods of manufacturing optical devices

Publication Date: 2013.10.15 UNIVERSITY OF MARIBOR

AI summary

Methods of manufacturing optical devices are disclosed. The method includes providing a structure-forming fiber bonded to at least one other optical component, the structure-forming fiber having a preferentially-etchable portion including at least one radial etching boundary and at least one axial etching boundary, and etching the preferentially-etchable portion to the radial and axial etching boundaries to produce a precise optical structure. The preferentially-etchable portion may be removed through one or more radial openings in the structure-forming fiber. Numerous other aspects are provided.