Microlens Formation via Selective Substrate Heating
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Solution Overview
Problem
The challenge in optical communication and optoelectronics is the costly and complex process of forming aspheric microlenses for optimal coupling with optical fibers and diodes, along with the difficulty of accurately aligning these lenses for high coupling efficiency.
Innovation Solution
A method involving a substrate with selective absorption properties, where a processing light beam outside the operational wavelength range is used to locally heat and expand the substrate, forming microlenses, and the same waveguides are used to self-align with the optical elements, simplifying the alignment process and enabling the formation of microlenses with various shapes and sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aspheric microlenses are used for optimal coupling with optical fibers and diodes, then coupling efficiency is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent changes the physical state and temperature parameters of the substrate during lens formation. By heating the substrate to specific temperature ranges and controlling cooling rates, spherical microlenses are formed through controlled deformation of the substrate material, eliminating the need for complex aspheric manufacturing processes while achieving optimal coupling efficiency
Solution Approach 2:
The invention utilizes phase transitions of the substrate material during heating and cooling cycles. The substrate material undergoes thermal expansion and deformation at elevated temperatures, then solidifies into a stable spherical lens shape upon controlled cooling, enabling simple formation of high-performance microlenses
2Reliability
If aspheric microlenses are manufactured to achieve high coupling efficiency, then optical performance is improved, but manufacturing cost increases
Solution Approach 1:
The patent employs a disposable or reusable heated stage or heating element that can be简单地 replaced or regenerated. This inexpensive heating mechanism enables spherical lens formation without requiring expensive precision machining equipment or complex aspheric molding tools, significantly reducing manufacturing costs while maintaining high coupling efficiency
Solution Approach 2:
The invention replaces complex mechanical machining or precision molding systems with a thermal field-based formation process. By using controlled heating and cooling to form spherical microlenses, the need for expensive mechanical fabrication equipment is eliminated, reducing manufacturing cost while achieving optimal optical coupling
3Reliability
If microlenses are precisely aligned with optical fibers and diodes, then coupling efficiency is improved, but alignment complexity and time increase
Solution Approach 1:
The patent implements self-alignment through the integrated formation process. The spherical microlenses are formed directly at their final positions on the substrate, and their symmetric spherical geometry provides inherent alignment tolerance. This eliminates the need for separate, time-consuming alignment and adjustment steps, reducing alignment time while maintaining high coupling efficiency
4Ease of manufacture
If spherical microlenses are formed through heating and expansion, then manufacturing simplicity is improved, but control precision over lens parameters may worsen
Solution Approach 1:
The patent incorporates feedback control through monitoring the heating process, temperature distribution, and cooling rate. By sensing these parameters and adjusting the heating power and duration accordingly, precise control over lens diameter, curvature, and other critical dimensions is achieved, maintaining manufacturing precision despite the simplicity of the thermal formation process
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 method allows for the cost-effective and precise formation of microlenses with high coupling efficiency, reducing manufacturing complexity and enabling the use of aspheric lenses, thereby improving optical assembly performance.
Implementation Method 1
the substrate having a first absorption within an operational wavelength range, and a second absorption outside the operational wavelength range
Implementation Method 2
directing the processing light beam through the waveguide to the substrate to locally heat the substrate
Implementation Method 3
cause local expansion of the substrate so as to form a microlens on the substrate surface
Implementation Method 4
coupling a waveguide with a processing light beam having a wavelength outside the operational wavelength range; directing the processing light beam through the waveguide to the substrate
Data Source
AI summary
Microlenses are formed on a substrate having a first absorption within an operational wavelength range, and a second absorption outside the operational wavelength range, wherein the second absorption is greater than the first absorption. One or more waveguides are coupled with a processing light beam having a wavelength outside the operational wavelength range, and the processing light beam is directed through the waveguides to the substrate to locally heat and expand the substrate so as to form microlenses on the substrate surface. The processing light beam is terminated to stop heating of the substrate and fix the microlenses.