Monolithic Collimator Array with Integral Lenses
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Solution Overview
Problem
Existing fiber optical collimator arrays face challenges due to mechanical deformations and inaccuracies in the alignment of fiber and lens arrays, leading to degraded performance from misalignment, especially angular twisting, which cannot be compensated for.
Innovation Solution
A collimator array is constructed from a solid block of transparent material with integral lens and fiber alignment holes, ensuring precise positioning through molding or other precise manufacturing methods, allowing for improved alignment accuracy and reduced assembly errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate fiber array and lens array are mechanically aligned, then assembly flexibility is improved, but alignment accuracy deteriorates
Solution Approach 1:
The patent merges the fiber array and lens array into a single monolithic block, where both arrays are formed integrally within the same substrate. This eliminates the separate assembly process and ensures that the relative positions of fibers and lenses are determined by the precision of the molding process rather than mechanical alignment, thereby resolving the contradiction between assembly flexibility and alignment accuracy.
Solution Approach 2:
The monolithic block is segmented into distinct functional regions: fiber insertion holes, lenses, and support structures. Each region is precisely formed during the molding process, allowing independent optimization of each component's position and geometry while maintaining overall integration, thus achieving high alignment accuracy without separate assembly.
2Device complexity
If mechanical alignment process is used, then device complexity is reduced, but alignment time increases
Solution Approach 1:
The fiber array and lens array positions are predetermined and fixed during the molding process itself. The mold cavities are designed with precise dimensions and positions, so that when the block is molded, the fibers and lenses are automatically positioned with high accuracy. This preliminary positioning action eliminates the need for time-consuming post-manufacturing alignment procedures.
3Ease of operation
If angular twisting misalignment occurs, then assembly ease is improved, but beam quality deteriorates
Solution Approach 1:
By combining the fiber array and lens array into a single monolithic structure, the patent eliminates the relative angular twisting misalignment that occurs in separately assembled systems. The integral formation ensures that the optical axes of all lens-fiber pairs are precisely aligned in the same plane, preventing beam fanning and maintaining high beam quality while simplifying assembly.
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 solution provides higher alignment accuracy and reduced production costs by integrating lens and fiber arrays within a single block, enhancing the collimation performance and maintaining accuracy across the array width.
Implementation Method 1
an array of lenses adapted to collimate light emitted from the ends of the optical fibers and impinging on the lenses
Data Source
AI summary
A collimator array using a molded element to hold the input fibers and to collimate the light. The input fibers are held within holes in one face of the element, and the collimation of the light emitted from the ends of the fibers is performed by an array of lenses appropriately located such that each lens collimates the light emitted from a fiber end. The lateral spacing between the holes is made to be equal to the lateral spacing between the lenses of the array. Since, in a molded element, this lateral spacing can be accurately provided, good alignment of the input fibers with the lenses can be achieved. The depths of the holes can be made such that when a fiber is inserted right to the bottom of a hole, the end of that fiber is accurately located such that the light emitted therefrom is collimated by the lens. This avoids the need for accurate manual alignment of the fibers of the array. Alternatively, the hole can be made slightly deeper than this predetermined depth, to provide some adjustment in the lens-fiber distance for adjusting the level of collimation.