Precision Fiber-Collimator-Array Alignment via Offset Lens Positioning
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Solution Overview
Problem
Existing multichannel optical rotary joints require complex and time-consuming adjustments of individual lenses for precise alignment, leading to increased system size and optical attenuation, and high manufacturing costs due to complex assembly processes.
Innovation Solution
A fiber optic collimator system with a micro lens array and a substrate-based fiber array where fibers are positioned against the same side of holes, allowing for easier alignment and assembly, using methods like centrifugal force, magnetic forces, or surface tension to maintain precise positioning, and utilizing softer material restrictions to guide fiber placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual lenses are adjusted for precise alignment in multichannel optical rotary joints, then alignment precision is improved, but system size and adjustment time increase
Solution Approach 1:
The patent merges multiple individual lens adjustments into a single integrated micro lens array where all lenses are pre-aligned relative to each other. The fiber array and lens array are positioned as integrated units, eliminating the need for individual lens adjustments and reducing system complexity while maintaining alignment precision.
Solution Approach 2:
The micro lens array serves as a universal alignment structure for all optical channels simultaneously. The substrate-based fiber array provides a common reference plane that enables all fibers to be aligned with their corresponding lenses in a single positioning operation, rather than requiring separate adjustment mechanisms for each channel.
2Manufacturing precision
If individual lenses are adjusted for precise alignment, then alignment precision is improved, but adjustment time increases
Solution Approach 1:
The alignment precision is achieved through preliminary positioning during manufacturing. The substrate-based fiber array and micro lens array are designed with pre-defined geometric relationships, allowing all fibers to be aligned with their corresponding lenses in a single positioning operation rather than requiring iterative individual adjustments.
Solution Approach 2:
The patent combines all alignment operations into a single integrated positioning step. The micro lens array and fiber array are aligned as unified structures, eliminating the time-consuming sequential adjustment of individual lenses and fibers that would otherwise be required.
3Quantity of substance
If more channels are added to increase transmission capacity, then communication bandwidth is improved, but system size and optical attenuation increase
Solution Approach 1:
The patent uses identical replicated structures for each optical channel - the substrate-based fiber array and micro lens array provide uniform, precise positioning for multiple channels. This standardized copying of alignment structures across channels increases channel density without proportionally increasing system size, as each channel uses the same compact geometry.
4Ease of manufacture
If traditional fiber positioning methods are used with larger holes, then ease of assembly is improved, but positioning precision deteriorates
Solution Approach 1:
The substrate-based fiber array enables self-aligning fiber positioning. The micro lens array and fiber array are designed with complementary geometric features that automatically guide alignment when the arrays are brought together, eliminating the need for complex external alignment tools or procedures while achieving high positioning precision.
Data Source
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AI summary
A collimator system comprises a micro lens array and a fiber array. The fiber array has a substrate with a plurality of holes for holding a plurality of optical fibers. The fibers are glued into the holes. Furthermore before gluing, each of the fibers is positioned against the same side of its hole resulting in all fibers being located equally with respect to the holes. The lens array is mounted with an offset to the fiber array resulting in alignment of the fibers and the lenses.