Optical Circuit Switch Collimator Using Glass Lens Array
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Solution Overview
Problem
Existing optical circuit switch collimators using etched silicon or polymer lens arrays fail to meet desired performance characteristics such as insertion loss, beam waist diameter consistency, and beam pointing accuracy.
Innovation Solution
A collimator device with a fiber array and an optical lens array aligned using a spacer with refractive index matching epoxies, where the lenses are made of molded glass with uniform curvature and pitch error, ensuring precise alignment and low insertion loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If etched silicon or polymer lens arrays are used in optical circuit switch collimators, then manufacturing complexity is reduced, but performance characteristics such as insertion loss, beam waist diameter consistency, and beam pointing accuracy deteriorate
Solution Approach 1:
The patent combines molded glass lens arrays with precision spacers and epoxy bonding materials to create a composite collimator structure. The glass substrate provides optical precision while the spacer and epoxy provide mechanical stability and alignment, achieving both manufacturing feasibility and high performance
Solution Approach 2:
The patent introduces a spacer as an intermediary element between the lens array and the fiber array. This spacer provides precise mechanical positioning and maintains uniform spacing, enabling accurate alignment without requiring direct integration of the lens array with the fibers
2Ease of manufacture
If etched silicon or polymer lens arrays are used in optical circuit switch collimators, then manufacturing cost is reduced, but insertion loss performance deteriorates
Solution Approach 1:
The use of molded glass lens arrays on a glass substrate with optimized optical properties reduces scattering and absorption losses. The combination of glass materials with matched refractive indices minimizes interface losses while maintaining manufacturability through molding processes
3Device complexity
If simple lens arrays are used in optical circuit switch collimators, then device complexity is reduced, but beam pointing accuracy deteriorates
Solution Approach 1:
The spacer acts as a precision intermediary that mechanically enforces uniform spacing between the lens array and fiber array. This simple yet effective mechanism achieves accurate beam pointing without complex active alignment or control systems
Solution Approach 2:
The lens array and fiber array are pre-aligned during assembly using the spacer as a mechanical reference. This preliminary alignment action ensures accurate beam pointing before the device is put into operation, eliminating the need for complex real-time adjustment mechanisms
4Ease of manufacture
If non-uniform spacing is used between lens array and fiber array, then manufacturing is simplified, but beam waist position consistency deteriorates
Solution Approach 1:
The spacer serves as a rigid intermediary that mechanically guarantees uniform spacing between the lens array and fiber array. Its fixed thickness provides a stable reference dimension that maintains consistent beam waist positioning across all channels while simplifying the manufacturing process
Solution Approach 2:
The uniform spacing is pre-established by the spacer geometry during assembly. This preliminary structural configuration ensures that all subsequent optical operations occur at the correct distances, maintaining beam waist position consistency without requiring complex manufacturing tolerances
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 achieves improved fiber coupling efficiency and low insertion loss, with a consistent beam waist size and position, enhancing the performance of optical circuit switches.
Implementation Method 1
An optical lens array is aligned and optically coupled to the fiber array
Data Source
Figure 1
Figure 2A~2B
Figure 3A
AI summary
A collimator device and a collimator lens array for an optical circuit switch are provided. The collimator includes a fiber array including multiple optical fibers disposed in a hole array. An optical lens array is aligned and coupled to the fiber array. A spacer is disposed between the fiber array and the optical lens array and provides substantially uniform spacing between lenses in the optical lens array and corresponding fibers in the fiber array. Multiple pads are positioned along edges of a surface of the spacer facing the optical lens array defining a first separation gap between the spacer and the optical lens array. A first epoxy bonds the spacer to the optical lens array, and a second epoxy bonds the spacer to the fiber array. The optical lens array includes a glass substrate having a first surface defining lenses in a two-dimensional array.