3D Lithography Fiber Coupling Alignment Structure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for forming fiber coupling devices lack precise, individually optimized positioning of fiber coupling alignment structures, leading to reduced optical coupling efficiency and increased manufacturing effort and costs.
Innovation Solution
A method using three-dimensional laser printing to form fiber coupling alignment structures directly on a substrate, ensuring precise alignment and integration with optoelectronic or photonic elements, eliminating the need for additional adhesive layers and allowing for passive self-alignment of optical fibers with high coupling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If preshaped structures such as shrinked boot parts or preshaped parts molded by injection molding are used as fiber coupling alignment structures, then the fiber coupling alignment structures can be formed with defined contours, but the positioning precision relative to the substrate is degraded due to additional mounting steps and adhesive layers
Solution Approach 1:
The patent merges the fiber coupling alignment structure formation with the substrate fabrication process itself. The alignment structures are formed directly on the substrate surface using laser-induced polymerization of a polymerizable material, eliminating the need for separate molding and mounting steps. This integration ensures precise positioning relative to the optoelectronic or photonic elements on the substrate.
Solution Approach 2:
The patent replaces conventional mechanical molding and adhesive bonding methods with a direct laser-based polymerization process. The laser beam selectively polymerizes the polymerizable material directly on the substrate surface, forming the alignment structures with high precision without mechanical intervention or adhesive layers.
2Ease of manufacture
If conventional molding methods are used to form fiber coupling alignment structures, then the manufacturing process is simpler, but the tolerance margin for fiber mounting is reduced due to imprecise positioning
Solution Approach 1:
The patent replaces conventional mechanical molding methods with a direct laser-based polymerization process. The laser beam selectively polymerizes the polymerizable material directly on the substrate surface, forming the alignment structures with high precision without mechanical intervention or adhesive layers.
3Strength
If additional adhesive layers are used to mount fiber coupling alignment structures, then the structures can be attached to the substrate, but the optical coupling efficiency is reduced and manufacturing effort increases
Solution Approach 1:
The patent extracts and eliminates the adhesive layer from the fiber coupling alignment structure assembly. The alignment structures are formed directly on the substrate surface through laser-induced polymerization, removing the intermediate adhesive layer that degrades optical coupling efficiency and adds manufacturing complexity.
Solution Approach 2:
The patent merges the fiber coupling alignment structure formation with the substrate fabrication process itself. The alignment structures are formed directly on the substrate surface using laser-induced polymerization of a polymerizable material, eliminating the need for separate molding and mounting steps.
4Reliability
If active measurement and adjustment of light intensity is performed for fiber alignment, then the coupling efficiency can be optimized, but the manufacturing effort and costs increase
Solution Approach 1:
The patent performs preliminary action by pre-forming the fiber coupling alignment structures with precise contours and positioning directly on the substrate surface before fiber mounting. The laser-induced polymerization creates accurately defined alignment features that guide passive self-alignment, eliminating the need for active measurement and adjustment during fiber assembly.
Solution Approach 2:
The patent enables passive self-alignment where the fiber naturally aligns with the optoelectronic or photonic elements through the pre-formed alignment structures. The precisely defined contours and geometric features of the alignment structures provide self-guiding cues that eliminate the need for active measurement, monitoring, or adjustment of light intensity during 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 high optical coupling efficiency with a broader tolerance margin for fiber mounting, reducing manufacturing costs and effort while ensuring precise alignment without active measurement of light intensity, allowing for fast and inexpensive fiber coupling.
Implementation Method 1
a laser beam is used to locally solidify a polymerizable material applied to at least a portion of the substrate surface in a technique of 3D lithography
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The application provides a method of forming a fiber coupling device comprising at least one optoelectronic and/or photonic element (50) and a fiber coupling alignment structure (5) that is optically transmissive, - wherein the method at least comprises: a) applying a polymerizable material (2) to the substrate surface (16) of the substrate (15), b) selectively polymerizing, using a method of 3D lithography, a region of the polymerizable material (2) so as to convert the region of the polymerizable material (2) into a polymer material (4), thereby forming at least one fiber coupling alignment structure (5) that comprises: - a support interface surface (6) at which the polymer material (4) is in direct contact with the substrate surface (16) of the substrate (15), - a fiber support region (7) adapted to support at least one optical fiber in an aligned position for optical coupling to the substrate (15), and - a reflection surface (8) for reflecting light propagating between an optical fiber and the substrate (15), and c) cleaning the substrate (15) and the polymer material (4) from remaining non-polymerized polymerizable material (2), thereby exposing the at least one fiber coupling alignment structure (5) of the fiber coupling device (1).