Lens Waveguide Alignment Using Optical Light Spots
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Solution Overview
Problem
Existing methods for aligning fiber arrays with lens arrays to form collimators are complex and costly, often lacking accurate fiducials for precise alignment, resulting in suboptimal collimator performance.
Innovation Solution
A system that uses a light source to create alignment marks on a lens block, allowing for precise alignment of waveguides with lenses by overlapping light spots with corresponding waveguide cores, followed by adhesive bonding to form a collimator with low divergence and high accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional alignment methods are used for fiber arrays with lens arrays, then alignment can be achieved, but the process becomes complex and costly with suboptimal performance
Solution Approach 1:
The patent introduces light spots as an intermediary alignment marker between the lens array and fiber array. The light spots are generated by illuminating the lens array from the object side, and these spots serve as visual targets for aligning the fiber cores with the respective lenses, simplifying the alignment process while achieving high precision
Solution Approach 2:
The patent replaces complex mechanical alignment systems with an optical alignment system. Instead of using mechanical fiducials or physical registration features, the invention uses optical light spots generated through the lens array to indicate alignment positions, thereby reducing mechanical complexity while improving alignment accuracy
2Manufacturing precision
If traditional alignment methods are used for fiber arrays with lens arrays, then alignment can be achieved, but the cost increases
Solution Approach 1:
The lens array itself generates the alignment markers (light spots) when illuminated, meaning the system aligns itself without requiring external alignment fixtures or complex equipment. This self-aligning capability reduces manufacturing costs while maintaining high precision
Solution Approach 2:
The light spots create an optical copy or representation of the lens array positions that can be easily observed and used for alignment. This optical copying method is simpler and cheaper than using physical fiducials or complex mechanical registration systems
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 system enables quick and accurate alignment of waveguides with lenses, achieving a high-quality collimator with divergence as low as 0.1-0.2 degrees, reducing costs and improving collimator performance.
Implementation Method 1
a light source configured to emit collimated light that causes the lens block to produce a plurality of light spots
Implementation Method 2
a first block including a plurality of lenses located on or near a first surface of the first block. The plurality of lenses are configured to receive light to generate a plurality of light spots
Data Source
AI summary
A system comprises a first mechanism configured to hold a first block including a plurality of lenses located on or near a first surface of the first block. The plurality of lenses are configured to receive light to generate a plurality of light spots at or near a second surface of the first block opposite the first surface. The system includes a second mechanism configured to hold a second block including a plurality of waveguides, and to move the second block to bring the plurality of waveguides in alignment with the plurality of lenses using the plurality of light spots as alignment marks.