Monolithic Optical Apparatus Laser Alignment
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Solution Overview
Problem
The alignment and bonding of fibre arrays with microlens arrays in fibre optic applications require sub-micron accuracy, which is a complex and time-consuming process, and existing methods lack efficient and accurate methods for forming optical elements and alignment holes simultaneously.
Innovation Solution
The use of laser modification and laser ablation to form optical elements and alignment holes in a monolithic block of material, allowing for simultaneous creation of optical elements and alignment holes without moving the body, enabling precise alignment and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fibre arrays and lens arrays are provided separately and aligned manually, then alignment accuracy can be achieved, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent merges the fibre array and lens array into a single monolithic body, where both the optical elements (lenses) and alignment holes are formed in the same material block. This integration eliminates the need for separate alignment and bonding processes, reducing manufacturing complexity while maintaining sub-micron alignment accuracy through the precise formation of alignment holes during the same laser processing procedure that creates the optical elements.
Solution Approach 2:
The alignment holes are formed in advance during the laser processing procedure that creates the optical elements, before any assembly or bonding operations. This preliminary formation of alignment features ensures that the relative positions of optical elements and alignment holes are established with high precision from the outset, eliminating the need for subsequent alignment operations.
2Ease of operation
If fibre arrays and lens arrays are bonded separately, then assembly flexibility is maintained, but alignment time increases significantly
Solution Approach 1:
By combining the fibre array and lens array into a single monolithic structure with integrated alignment holes, the patent eliminates the time-consuming separate bonding process. The alignment holes are formed during the same laser processing procedure that creates the optical elements, reducing alignment time from a complex multi-step process to a single integrated manufacturing step.
3Ease of manufacture
If separate laser processing procedures are used for optical elements and alignment holes, then process control is simplified, but manufacturing time increases
Solution Approach 1:
The patent merges the formation of optical elements and alignment holes into a single laser processing procedure. The laser system processes the monolithic block to create both the optical elements and the alignment holes in one continuous operation, eliminating the need for separate processing steps and significantly improving manufacturing efficiency while maintaining precise control over both features.
4Manufacturing precision
If multiple processing steps are used for forming optical elements and alignment holes, then feature quality can be optimized, but overall manufacturing complexity increases
Solution Approach 1:
The patent combines the formation of optical elements and alignment holes into a single laser processing procedure acting on a monolithic block. This integration reduces the number of processing steps from multiple separate operations to one unified process, while the laser system maintains high precision for both feature types through controlled processing parameters and a single setup operation.
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 approach simplifies the manufacturing of lens-coupled fibre arrays by ensuring accurate alignment and positioning of optical elements and alignment holes, reducing complexity and improving the efficiency of fibre optic applications.
Implementation Method 1
The optical elements and the alignment holes may be formed by laser modification of the material and/or by laser ablation.
Implementation Method 2
The laser modification of the material and/or the laser ablation may comprise a laser processing procedure that comprises holding the body in position using a sample stage and providing relative movement between a laser beam and the sample stage.
Data Source
AI summary
Optical apparatus comprises:a body comprising material;a plurality of optical elements formed of the material of the body; anda plurality of alignment holes formed in the material of the body,wherein:the alignment holes comprise fibre or other waveguide alignment holes aligned with one or more of the optical elements, and/orthe alignment holes comprise alignment holes configured to receive mechanical elements for fixing and/or aligning the body to at least one further body.