Optical Component Alignment via Nested Transmission Regions
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Solution Overview
Problem
Existing optical assemblies face misalignment issues due to tilted observation axes, leading to decreased coupling efficiency between optical fibers and light receiving/emitting elements, as centering methods relying on imaging devices can result in the optical lens array being deviated from the desired position.
Innovation Solution
An optical component comprising a substrate with reference marks and a lens component with first and second transmission regions, where the second transmission regions are smaller than the first, allowing for precise alignment and centering such that the reference marks are within the second transmission regions when viewed orthogonally, ensuring accurate optical coupling and reducing foreign matter entry without the need for additional lids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If centering methods using imaging devices are used to align optical components, then alignment can be performed, but the optical lens array may be deviated from the desired position due to tilted observation axes, decreasing coupling efficiency
Solution Approach 1:
The lens component is divided into multiple transmission regions (first transmission regions on the outer surface and second transmission regions on the inner surface) that are spatially separated and sized differently. This segmentation allows the outer transmission regions to serve as alignment markers while the inner regions provide the actual optical function, enabling independent optimization of alignment accuracy and optical performance.
Solution Approach 2:
The first transmission regions act as intermediary alignment markers that mediate between the external imaging device and the internal optical components. By providing distinct outer transmission regions that are larger and easier to image, the system enables accurate centering without requiring direct imaging of the smaller inner transmission regions or optical components, thus eliminating the tilted observation axis problem.
2Object-affected harmful factors
If additional lids are added to suppress foreign matter entry into the optical assembly, then foreign matter protection is improved, but the component count and manufacturing complexity increase
Solution Approach 1:
The lens component is designed to perform multiple functions simultaneously: it provides optical transmission through the inner transmission regions, serves as an alignment reference through the outer transmission regions, and acts as a protective barrier against foreign matter entry. By integrating these functions into a single component, the invention eliminates the need for separate lids while maintaining foreign matter protection.
Solution Approach 2:
The protective function previously requiring a separate lid is merged into the lens component itself. The lens component's structure is designed to seal the optical assembly while maintaining optical functionality, combining the protective barrier function with the optical transmission and alignment functions in a single integrated element.
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
Improves the efficiency of optical coupling between the optical device and the lens, provides a low-cost solution with a low component count, and enhances alignment reliability by using a simple alignment mechanism that suppresses foreign matter entry.
Implementation Method 1
a lens configured to optically couple to the optical device
Implementation Method 2
the optical fiber is optically coupled to the optical device through the lens
Data Source
AI summary
An optical component including an optical device, a substrate, and a lens component is disclosed. The substrate has a mounting surface on which the optical device is mounted and at least two reference marks are provided. The lens component is disposed on the substrate. The lens component includes a first surface, a second surface, a lens, at least two first transmission regions formed on the first surface, and at least two second transmission regions formed in positions facing the first transmission regions on the second surface. Each of the second transmission regions is smaller than the corresponding first transmission region. The lens component is attached to the substrate so that each of the second transmission regions is located within the corresponding first transmission region and each of the reference marks is located within the corresponding second transmission region when viewed along an observation direction orthogonal to the first surface.