Integrated Optical Multiplexer Molded Product Manufacturing
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Solution Overview
Problem
Existing optical multiplexers require separate manufacturing of microlens arrays and optical blocks, leading to poor productivity and size limitations, as well as the need for additional optical components to change the optical path in the vertical direction, increasing unit costs.
Innovation Solution
A method involving mold processing to form a single molded product with integrated microlens arrays and optical blocks, which is then cut in a row direction to produce multiple optical multiplexers, eliminating the need for optical alignment and reducing the size of the optical block, allowing for multiplexing or demultiplexing in a vertical direction without additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If microlens array and optical block are manufactured as separate parts requiring optical alignment, then manufacturing precision can be maintained for each component, but productivity deteriorates due to complex assembly processes
Solution Approach 1:
The patent merges the microlens array and optical block into a single integrated molded product. The mold includes both microlens array forming cavities and optical block forming cavities, allowing simultaneous formation of both components in one molding process. This eliminates the need for separate manufacturing and optical alignment operations, directly resolving the contradiction by improving productivity while maintaining manufacturing precision through the integrated mold design.
2Loss of energy
If optical block size is reduced to minimize optical path length, then signal loss is reduced, but manufacturing precision becomes more difficult to maintain
Solution Approach 1:
The patent applies preliminary action by pre-forming the optical block with the exact minimized dimensions and integrated microlens array positions during the molding process. The mold cavities are designed to create the optimal optical path length from the start, eliminating the need for subsequent precision adjustments or alignments. This preliminary formation of the integrated structure maintains manufacturing precision while achieving the desired minimal optical path length to reduce signal loss.
3Adaptability or versatility
If additional optical components are provided to change optical path in vertical direction, then optical path flexibility is improved, but device complexity and unit cost increase
Solution Approach 1:
The patent makes the optical block multi-functional by integrating the microlens array directly into it. The optical block serves both as the structural component and as the optical focusing element through the integrated microlens array. This eliminates the need for additional separate optical components to change the optical path in the vertical direction, maintaining optical path flexibility while reducing device complexity and unit cost.
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 significantly enhances productivity by integrating microlens arrays and optical blocks, reduces signal loss through minimized optical path lengths, and eliminates the need for separate optical components, thereby improving mass production efficiency and reducing costs.
Implementation Method 1
a first aspherical microlens layer 131b having aspherical surfaces and formed on a second surface of the base part 130a
Implementation Method 2
optical filters 12 each of which selectively transmitting only a specific wavelength of a beam incident on the microlens array
Implementation Method 3
an optical block 13 for reflecting and combining beams of different wavelengths λ1, λ2, λ3, and λ4 incident on the filters 12
Data Source
AI summary
A method of manufacturing an optical multiplexer, whereby one molded product is formed by using a mold and vertically cut in a row direction, thus efficiently manufacturing multiple optical multiplexers, with a microlens array and an optical block being integrated together. Therefore, the present invention may increase product productivity and realize a size reduction of a product.