Lens Array Prism Recessing for Adhesive Flow Control
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Solution Overview
Problem
Existing lens arrays face challenges in maintaining optical characteristics due to adhesive formation on the optical path, which compromises the efficiency of monitor light generation and multichannel optical communication, particularly in compact designs with increased channels.
Innovation Solution
A lens array design featuring a prism placement recessing section with air-bubble retention prevention recessing sections and an adhesive flow prevention recessing edge section, which prevents adhesive retention on the optical path and allows for the use of high contraction coefficient adhesives, ensuring efficient monitor light generation and simplified manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a prism is bonded within a recessing section of the lens array main body using a light-transmissive adhesive, then the monitor light can be obtained with certainty by the reflective/transmissive layer dividing the light, but the adhesive may be formed on the optical path as foreign matter that compromises optical characteristics
Solution Approach 1:
The recessing section is divided into multiple functional regions: a prism placement region for positioning the prism, and a adhesive excess retention region for capturing overflowed adhesive. This segmentation prevents adhesive from reaching the optical path while ensuring proper prism bonding and monitor light generation.
Solution Approach 2:
The adhesive excess retention region acts as an intermediary zone between the prism placement region and the optical path. It captures and holds excess adhesive, preventing direct contact between the adhesive and the optical path, thus protecting optical characteristics while maintaining bonding functionality.
2Productivity
If the lens array is designed with increased channels and size reduction, then the compactness and channel capacity improve, but the precision of adhesive placement becomes more critical to avoid optical path contamination
Solution Approach 1:
The adhesive excess retention region is pre-configured in the recessing section structure before adhesive application. This preliminary design ensures that when adhesive is applied, any excess automatically flows into the designated retention region rather than contaminating the optical path, reducing the precision requirements for adhesive placement in compact high-channel designs.
3Ease of manufacture
If a high contraction coefficient adhesive is used to simplify manufacturing, then the ease of manufacture improves, but the adhesive may shrink and form voids or affect optical characteristics
Solution Approach 1:
The harmful effect of adhesive shrinkage is extracted and isolated into the adhesive excess retention region. This region accommodates volume changes and void formation without affecting the optical path, allowing the use of high contraction coefficient adhesives that are easier to apply while maintaining optical characteristics.
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
The design effectively prevents adhesive-related optical path issues, enabling efficient monitor light generation, size reduction, increased channels, improved yield, and simplified operability in lens arrays.
Implementation Method 1
a total reflection surface that is formed on a third surface of the lens array main body on a side opposite to the first surface, such as to oppose the plurality of first lens faces, and that totally reflects the light of each of the plurality of light-emitting elements that has entered the plurality of first lens faces towards the side of the plurality of second lens faces
Implementation Method 2
a reflective/transmissive layer that is disposed on an incident surface of the prism for the light of each of the plurality of light-emitting elements, the reflective/transmissive layer reflecting the light of each of the plurality of light-emitting elements that has been totally reflected by the total reflection surface towards the third lens face side at a predetermined reflection factor and transmitting the light of each of the plurality of light-emitting elements that has been totally reflected by the total reflection surface towards the incident surface side at a predetermined transmission factor
Implementation Method 3
a reflective/transmissive layer that is disposed on an incident surface of the prism for the light of each of the plurality of light-emitting elements, the reflective/transmissive layer reflecting the light of each of the plurality of light-emitting elements that has been totally reflected by the total reflection surface towards the third lens face side at a predetermined reflection factor and transmitting the light of each of the plurality of light-emitting elements that has been totally reflected by the total reflection surface towards the incident surface side at a predetermined transmission factor
Implementation Method 4
a first air-bubble retention prevention recessing section that is formed in a recessing manner on the third surface such as to communicate with the prism placement recessing section in one array direction and such as to be off of the optical path of the light of each of the plurality of light-emitting elements, and that prevents retention of air-bubbles in the adhesive on the optical path of the light of each of the plurality of light-emitting elements between the prism placement recessing section and the prism during adhesion of the prism
Implementation Method 5
an adhesive flow prevention recessing edge section that is formed in a recessing manner on the third surface such as to surround respective openings of the prism placement recessing section, the first air-bubble retention prevention recessing section, and the second air-bubble retention recessing section, and that prevents flow of the adhesive onto the total reflection surface during adhesion of the prism
Data Source
AI summary
A lens array is provided with a prism adhered within a prism placement recessing section by an adhesive, wherein retention of air-bubbles in the adhesive on an optical path of light of each light-emitting element between the prism placement recessing section and the prism is prevented by a first air-bubble retention prevention recessing section and a second air-bubble retention prevention recessing section that communicate with the prism placement recessing section in a lens array direction, and flowing of the adhesive onto a total reflection surface is prevented by an adhesive flow prevention recessing edge section.