Expanded Beam Lens Assembly with Compliant Layer
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Solution Overview
Problem
Multi-lens optical fiber assemblies used in harsh and high-vibration environments are costly due to complexity and tight tolerance requirements, necessitating a low-cost, manufacturable solution with improved reliability for light transmission.
Innovation Solution
A molded optical fiber assembly featuring a lens block with complementary arcuate lens surfaces of different refractive indices, integrated beam expanding and collimating elements, and a compliant layer to minimize optical interference and enhance manufacturability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-lens assemblies are used to expand the optical beam, then light transmission reliability is improved, but manufacturing cost increases due to complexity and tight tolerance requirements
Solution Approach 1:
The patent combines multiple lens functions (beam expansion and collimation) into a single integrated lens assembly with a specific dual-curved surface design, eliminating the need for separate lens components and reducing manufacturing complexity while maintaining optical performance
Solution Approach 2:
The patent modifies the lens surface geometry by implementing complementary arcuate surfaces with specific radii of curvature, transforming the optical path to achieve both beam expansion and collimation in a single lens element, thereby simplifying manufacturing while preserving reliability
2Manufacturing precision
If multi-lens assemblies with tight tolerance control are used, then optical alignment precision is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple optical functions into a single lens assembly, reducing the number of components that require alignment and thereby decreasing overall device complexity while maintaining manufacturing precision through the integrated design
Solution Approach 2:
The patent employs complementary arcuate surfaces with specifically designed radii of curvature that inherently guide light through the desired optical path, reducing the need for tight mechanical tolerances and simplifying the alignment process while maintaining optical precision
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 solution provides a cost-effective, reliable, and efficient optical fiber assembly that maintains light transmission integrity in harsh environments by reducing manufacturing complexity and minimizing optical interference, while ensuring alignment and beam collimation.
Implementation Method 1
Each beam expanding and collimating element includes a first lens and a second lens. The first lens includes a generally arcuate first lens surface. The second lens includes a generally arcuate second lens surface. The first lens surface and the second lens surface are generally complementary in shape and in contact with each other. Each of the first lens and the second lens have a different index of refraction.
Data Source
AI summary
An optical fiber assembly includes a lens block with a plurality of beam expanding and collimating elements. Each beam expanding and collimating element includes a first lens and a second lens. The first lens includes a generally arcuate first lens surface and the second lens includes a generally arcuate second lens surface generally complementary in shape and in contact with the first lens. Each lens has a different index of refraction. An optical fiber assembly may include a housing with a plurality of beam expanding elements. A front portion of each beam expanding element has a generally planar front surface. A compliant layer is positioned on the generally planar front surface of each beam expanding element.