Optical Component Alignment Using Etch Pit Mediators
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Solution Overview
Problem
Integrated optical bench systems face misalignment issues due to non-perpendicular edges of optical components, leading to errors and losses in the system.
Innovation Solution
The use of etch pits with alignment edges formed using deep reactive ion etching techniques, where optical components are aligned such that their edges are in substantial physical contact with the pit's alignment edges, ensuring precise alignment regardless of the components' perpendicularity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If optical components are made using macromachining techniques, then manufacturing complexity is reduced, but manufacturing precision deteriorates due to inability to achieve perpendicular edges
Solution Approach 1:
The patent introduces an intermediary alignment structure consisting of etch pits with precision alignment edges formed by deep reactive ion etching. These alignment edges serve as mediators between the optically active surfaces and the mounting substrate, enabling precise alignment without requiring the optical components themselves to have perfectly perpendicular edges. The alignment edges act as reference features that facilitate accurate positioning while the optical surfaces maintain their functional independence.
2Manufacturing precision
If optical components are made using micromachining techniques, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent segments the alignment function from the optical component manufacturing. Instead of requiring the entire optical component to be manufactured with high precision micromachining, only the alignment edges are created using deep reactive ion etching, while the optically active surfaces can be manufactured using less complex macromachining techniques. This segmentation allows different manufacturing techniques to be applied to different portions of the system based on their specific requirements.
3Ease of manufacture
If optical component edges are not perpendicular, then ease of manufacture is improved, but alignment accuracy deteriorates leading to system errors and losses
Solution Approach 1:
The alignment edges formed by deep reactive ion etching serve as intermediary reference features that decouple the alignment accuracy from the perpendicularity of the optical surfaces. These intermediary alignment structures provide precise geometric references for positioning, allowing optical components with non-perpendicular edges to be accurately aligned through physical contact with the alignment edges rather than relying on the perpendicularity of the optical surfaces themselves.
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 effectively reduces errors and losses by ensuring accurate alignment of light paths, allowing for precise orientation and minimization of irregularities in optical systems.
Implementation Method 1
The use of etch pits with alignment edges formed using deep reactive ion etching techniques
Data Source
AI summary
Methods, apparatuses, and systems for alignment of an optical component are described herein. One method includes forming a pit in a substrate, placing an optical component in the pit, and aligning the optical component such that an edge of the optical component is in physical contact with an alignment edge of the pit.