GRIN Lens Separation from Rods via Carrier Segmentation

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Solution Overview

Problem

Conventional methods for manufacturing GRIN lenses from GRIN rods are labor-intensive and costly due to the complexity of processing parts with sub-millimeter features and precise optical surface requirements, making them unsuitable for consumer electronic applications that require high mating cycles and exposure to dirt and debris.

Innovation Solution

A method involving the separation of GRIN lenses from GRIN rods using a carrier with binding material, followed by optional polishing and insertion into optical devices, which simplifies the manufacturing process and reduces costs while maintaining optical quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional methods are used to manufacture GRIN lenses from GRIN rods with sub-millimeter features and precise optical surface requirements, then manufacturing precision is maintained, but device complexity and manufacturing cost increase significantly

Engineering Contradiction:

Improveoptical surface precisionVSAvoidprocessing complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent segments the GRIN rod processing into distinct stages: securing multiple GRIN rods in a carrier, selective cutting to separate lenses, and individual lens removal. This segmentation transforms a complex continuous processing challenge into manageable discrete steps, reducing overall device complexity while maintaining precision through controlled separation at predetermined locations

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies preliminary action by pre-securing multiple GRIN rods in the carrier at predetermined positions before cutting. This preliminary positioning and securing enables subsequent precise cutting and separation operations to be performed efficiently, reducing the complexity of handling individual rods during the critical separation phase

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If time-consuming manual polishing and laser cleaving are used to prepare precision surfaces, then manufacturing precision is improved, but productivity decreases

Engineering Contradiction:

Improveend face precisionVSAvoidmanufacturing speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent employs periodic action through automated cyclic operations: securing rods, cutting at predetermined intervals, removing lenses, and repeating the process. This periodic automated manufacturing cycle maintains precision through consistent repeated operations while significantly increasing productivity compared to manual polishing and cleaving performed on each rod individually

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The patent replaces manual mechanical polishing and laser cleaving operations with automated cutting and separation processes. This substitution eliminates time-consuming manual interventions while maintaining the required precision through controlled automated operations, thereby increasing manufacturing speed and productivity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If high-precision polishing equipment and consumables are used, then manufacturing precision is maintained, but manufacturing cost increases

Engineering Contradiction:

Improvesurface planarityVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent employs disposable carrier components and cutting elements that can be replaced without requiring expensive precision polishing equipment. The carrier and cutting tools are designed as single-use or limited-life components that maintain precision at lower cost, eliminating the need for costly high-precision polishing machinery and consumables while achieving the required surface quality

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the manufacturing approach from precision surface modification (polishing) to precision material removal (cutting). By altering the process parameter from surface finishing to controlled separation, the method achieves the required precision at lower cost through automated cutting processes that eliminate expensive polishing equipment requirements

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS9377565B2Processing of gradient index (GRIN) rods into GRIN lenses attachable to optical devices, components, and methods

Publication Date: 2016.06.28 CORNING OPTICAL COMMUNICATIONS LLC

AI summary

Embodiments for processing of gradient index (GRIN) rods into GRIN lenses attachable to optical devices, components, and methods are disclosed. A cylindrical GRIN rod comprises an optical axis and a longitudinal axis at a center axis, where the index of refraction may be greatest at the optical axis. The GRIN rod includes GRIN lenses along the longitudinal axis. The GRIN lenses include a first optical surface and a second optical surface opposite the first optical surface. Separation processes and devices may separate the GRIN lenses from the GRIN rods and these processes may be automated. Other processes may polish the first and the second optical surfaces. A gripper may insert the GRIN lens into an optical device.