Lens Block Alignment Feature for Optical Surface Verification
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Solution Overview
Problem
Complex optical surfaces in lens blocks of optical communications modules are difficult to align and measure accurately, leading to performance issues and narrower tolerance windows than designed, due to the lack of direct measurement methods and reliance on functional optical testing by precision mechanical experts with limited optics expertise.
Innovation Solution
An alignment feature is integrated into the lens block with a precise spatial relationship to complex optical surfaces, allowing for precise alignment and measurement of the alignment feature, which ensures the correct alignment of the optical surfaces, and adjustments can be made to the manufacturing process based on misalignment measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If functional optical testing is used to verify alignment of complex optical surfaces, then alignment can be assessed by overall lens block performance, but measurement precision is insufficient and tolerance windows are narrower than designed
Solution Approach 1:
The patent introduces an alignment feature as an intermediary element that has a precise spatial relationship to the complex optical surface. This alignment feature serves as a mediator that can be directly measured with high precision while indirectly indicating the alignment of the optical surface, thereby resolving the contradiction between verification capability and measurement precision
Solution Approach 2:
The alignment feature acts as a simplified copy or proxy of the complex optical surface alignment problem. Instead of directly measuring the complicated optical surface, the patent creates a measurable representation (alignment feature) that correlates to the optical surface alignment, enabling precise measurement without directly tackling the complexity of the optical surface itself
2Measurement precision
If direct measurement methods are used for complex optical surfaces, then measurement precision would improve, but device complexity increases due to lack of measurable features
Solution Approach 1:
The alignment feature serves as a simple intermediary that bridges the gap between the complex optical surface and the measurement system. It provides a straightforward geometric feature that can be measured using conventional, simple measurement tools, thereby improving measurement precision without increasing device or measurement system complexity
Solution Approach 2:
The patent changes the measurement parameter from directly measuring complex optical surface properties to measuring the geometric parameters of the alignment feature. This parameter transformation allows using simple geometric measurements instead of complex optical measurements, reducing device complexity while improving measurement precision
3Manufacturing precision
If passive and active alignment processes are used for lens block positioning, then positioning precision improves, but these processes cannot be used to align optical elements within the lens block
Solution Approach 1:
The alignment feature serves as a universal intermediary that can be used with both passive and active alignment processes. It provides a common reference that works across different alignment methodologies, enabling the versatile application of alignment processes to both external positioning and internal optical element alignment
Solution Approach 2:
The alignment feature provides a universal interface that makes alignment processes versatile. The same alignment feature can be utilized with different alignment processes (passive, active, direct measurement) and for different alignment objectives (lens block positioning, internal optical element alignment), thereby achieving multi-functionality
Data Source
AI summary
An alignment feature formed in a lens block during manufacturing has a precise spatial relationship to an optical surface of the lens block such that precise alignment of the alignment feature within the lens block ensures precise alignment of the optical surface within the lens block. Precise alignment of the alignment feature within the lens block is readily assessable whereas precise alignment of the optical surface within the lens block is not. A determination is made as to whether the optical surface is aligned within the lens block by determining whether the alignment feature is aligned within the lens block, and if not, the extent of any misalignment. The extent of misalignment may then be used to adjust the manufacturing process to eliminate the alignment error.