Fiber-Free OCT Integration on a Semiconductor Optical Bench
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Solution Overview
Problem
Existing Optical Coherence Tomography (OCT) and Optical Coherence Domain Reflectometry (OCDR) systems are costly and bulky due to the high cost of individual components and manufacturing, and the non-recurring expenses associated with photonic integrated circuits and semiconductor chip manufacturing, while redesigns and 'OCT-on-a-chip' approaches are not cost-effective.
Innovation Solution
Implementing OCT systems on semiconductor optical benches, which utilize micro-optics and eliminate the need for fiber optics, allowing for precise alignment and integration of components without active alignment processes, leveraging semiconductor manufacturing processes for scalability and cost reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If macroscopic OCDR/OCT systems are redesigned to reduce size and cost, then system size and manufacturing cost decrease, but component costs and overall manufacturing cost remain high
Solution Approach 1:
The system is divided into two distinct parts: a macroscopic OCT system for optical functionality and a microscopic optical bench for precise component positioning. This segmentation allows each part to be optimized independently - the macroscopic system for cost-effective manufacturing and the microscopic bench for precise alignment, thereby resolving the contradiction between size reduction and manufacturing cost.
Solution Approach 2:
The microscopic optical bench automatically maintains precise component positions through its rigid substrate structure and precision mounting features, eliminating the need for active alignment processes. This self-aligning capability reduces both system complexity and manufacturing cost while maintaining compact size.
2Volume of stationary object
If photonic integrated circuits are used to achieve size and cost reduction, then system size and operational cost decrease, but non-recurring expenses for R and D and manufacturing facility investment increase
Solution Approach 1:
The invention separates the optical processing functions (performed by standard OCT components) from the positioning functions (performed by the microscopic optical bench). This avoids the need for complex photonic integrated circuits while achieving compact size, thereby resolving the contradiction between size reduction and R&D investment.
Solution Approach 2:
The system uses standard, commercially available optical components mounted on a compact bench rather than expensive custom-fabricated photonic integrated circuits. This approach achieves size reduction using off-the-shelf components, avoiding the high NRE costs associated with PIC development and manufacturing facility investment.
3Manufacturing precision
If active alignment processes are used to integrate components, then component alignment precision improves, but system complexity and manufacturing cost increase
Solution Approach 1:
The microscopic optical bench is designed with precision mounting features and a rigid substrate structure that automatically maintain component positions without requiring active alignment processes. This self-aligning design achieves high manufacturing precision while eliminating complex alignment procedures, resolving the contradiction between alignment precision and system complexity.
Solution Approach 2:
Components are pre-positioned on the optical bench using precision mounting features during the manufacturing process. This preliminary positioning ensures accurate alignment is achieved during assembly without requiring complex active alignment processes during system operation or final assembly, thereby reducing device complexity.
Data Source
Figure 1A~1C
Figure 1D~1E
Figure 2A~2B
AI summary
An OCT system is constructed on a micro optical bench or semiconductor optical bench. The present OCT system may use free space optics and avoid the use of fiber optics.