Optical Assembly Using Convex Joint Element for Laser Alignment
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Solution Overview
Problem
Current optical assemblies for coupling laser beams to optical fibers face challenges such as high fabrication costs, complexity, and alignment issues due to stringent optical tolerances, and the use of adhesives can lead to mechanical instability and increased production costs.
Innovation Solution
An optical assembly that includes a pre-assembled collimator with a cylindrical sleeve and a joint element featuring a convex spherical surface, allowing for five degrees of freedom during alignment and minimizing the need for specialized components, along with a joint element that facilitates precise alignment and welding of the collimator to the package without interfering with the laser beam, thereby reducing assembly complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If active alignment and adhesive mounting techniques are used to connect the collimator to the laser package, then alignment precision can be achieved, but mechanical instability and increased production costs occur
Solution Approach 1:
The patent replaces the mechanical adhesive bonding system with a laser welding system. The joint element provides a welding interface that allows precise alignment to be maintained while achieving permanent mechanical bonding through laser welding, eliminating the mechanical instability associated with adhesives
Solution Approach 2:
The joint element acts as an intermediary component between the collimator and the laser package. It provides a stable mounting interface with features for precise alignment (such as positioning holes and flat surfaces) while also serving as the substrate for laser welding, thus mediating between alignment requirements and mechanical bonding requirements
2Manufacturing precision
If specialized collimators with spherical surfaces are fabricated to mate with convex surfaces, then alignment precision is improved, but fabrication costs and device complexity increase
Solution Approach 1:
The patent segments the alignment function from the collimator component itself and places it in the joint element. The joint element contains the convex spherical surface and positioning features, while the collimator uses a simpler cylindrical interface. This segmentation allows precise alignment features to be located where they are most effective (in the joint element) rather than requiring complex fabrication of the collimator
Solution Approach 2:
Instead of making the collimator complex with spherical surfaces to achieve precise mating, the patent inverts the approach by placing the spherical convex surface on the joint element that mates with the collimator's simpler cylindrical interface. This reverses which component bears the alignment complexity burden
3Adaptability or versatility
If multiple optical elements are placed in the free space within the package, then optical functionality is improved, but assembly complexity and manufacturing difficulty increase
Solution Approach 1:
The patent utilizes the third dimension (depth/length) of the joint element to accommodate multiple optical elements. The joint element is designed as an elongated component with a through-hole that can contain lenses, mirrors, or other optical elements along its length, allowing vertical stacking of optical functionality rather than horizontal arrangement
Solution Approach 2:
The joint element provides a nested structure where optical elements can be housed within its body or along its length. The through-hole and internal cavities of the joint element allow optical components to be nested within the assembly, integrating multiple functions into a compact hierarchical structure
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 enables efficient coupling of laser beams to optical fibers with improved alignment precision and reduced production costs, ensuring high mechanical resistance and reliability while maintaining low optical losses.
Implementation Method 1
a joint element (20) having a first surface (22a) which is to be brought in contact to a wall (4a) of the package from which the laser beam emerges and a second opposite surface (22b) which comprises a convex surface (23)
Implementation Method 2
The joint element and the collimator are then fixed by laser welding
Implementation Method 3
The collimator is designed to focus a collimated laser beam to an end of an optical fibre
Implementation Method 4
one or more signals are coupled between an optoelectronic device such as a laser and an optical fibre
Data Source
AI summary
An optical assembly includes an optical package having a wall with an aperture and includes a laser device capable of emitting a laser beam through the aperture and a collimator including a sleeve defining a first and a second end, the collimator including a terminating portion of an optical fiber. In addition, the assembly includes a joint element having a first and a second surface, the first surface contacting the wall around the aperture in a first contact area, and the second surface including a convex surface contacting a portion of the surface of the sleeve in correspondence of its first end in a second contact area, the convex surface being at least partially inserted in the sleeve, so that the collimator is aligned with respect to the laser beam.