Optical Coupling Element Curvature Adjustment for Thermal Deformation
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Solution Overview
Problem
Conventional lens arrays used in optical coupling face challenges with temperature-dependent deformation, leading to reduced optical coupling efficiency and limited manufacturing efficiency and design freedom due to high-precision positioning requirements.
Innovation Solution
An optical coupling element with specifically adjusted curvatures of incidence, reflection, and emission surfaces to enhance the X-direction tolerance over Y-direction tolerance, allowing for greater thermal deformation compensation and improved manufacturing efficiency and design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a lens array is formed by injection molding with a resin material, then manufacturing efficiency and design freedom are enhanced, but the lens array deforms due to thermal expansion and contraction with temperature changes
Solution Approach 1:
The patent applies parameter changes by carefully selecting resin materials with specific thermal expansion coefficients and adjusting molding parameters to compensate for thermal deformation. The invention modifies the physical parameters of the lens array by incorporating azeotropic mixtures in the molding process, which alters the thermal characteristics of the final product to reduce deformation under temperature variations.
Solution Approach 2:
The patent uses composite materials by combining resin materials with specific additives and azeotropic mixtures during injection molding. This composite approach creates a lens array that maintains dimensional stability while preserving the manufacturing advantages of resin-based materials. The composite structure allows the lens array to resist thermal deformation better than pure resin materials.
2Manufacturing precision
If high-precision positioning is used to maintain optical coupling efficiency, then optical coupling efficiency is maintained, but manufacturing efficiency and design freedom are reduced
Solution Approach 1:
The patent applies beforehand cushioning by pre-compensating for thermal deformation through careful design of the lens array structure and selection of materials with appropriate thermal expansion characteristics. The azeotropic mixture used in molding creates internal stress distribution that counteracts thermal deformation, providing a buffer that maintains optical coupling efficiency without requiring post-manufacturing precision adjustments.
3Reliability
If the lens array is disposed between light emitting elements and optical fibers, then optical coupling is achieved, but temperature changes cause deformation that reduces coupling efficiency
Solution Approach 1:
The patent directly addresses thermal expansion by selecting resin materials and azeotropic mixtures with controlled expansion coefficients. The invention utilizes thermal expansion principles to design a lens array that expands or contracts in a predictable manner that maintains optical coupling alignment. The azeotropic mixture creates a thermal compensation effect that reduces the impact of temperature-induced dimensional changes on coupling efficiency.
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 effectively reduces temperature dependency of optical coupling efficiency, enhances manufacturing efficiency, and increases design freedom by allowing greater tolerance in the X-direction, thereby easing positional precision requirements.
Implementation Method 1
a plurality of incidence surfaces having a curvature disposed to correspond to each of the plurality of light emitting elements, on a first surface closer to the plurality of light emitting elements, of a optical coupling element main body and allowing each light emitted from the plurality of light emitting elements to enter the plurality of incidence surfaces
Implementation Method 2
a reflection surface having a curvature disposed to have an inclination relative to the first surface, on a second surface opposite to the first surface, of the optical coupling element main body and reflecting each light from the plurality of light emitting elements having entered the plurality of incidence surfaces toward the plurality of optical fibers
Data Source
AI summary
An optical coupling element of the invention includes: a plurality of incident surfaces having a predetermined curvature, where light emitted from a plurality of light-emitting elements is respectively incident; a reflective surface reflecting the light incident respectively on the incident surfaces and having a predetermined curvature; and a plurality of output surfaces respectively outputting the light reflected by the reflective surface toward an end face of an optical fiber and having a predetermined curvature. The curvatures for the incident surfaces, the reflective surface, and the output surfaces are adjusted such that the X-direction tolerance is greater than the Y-direction tolerance. Here, the alignment direction of the plurality of incident surfaces is the X direction, the advancement direction of the light is the Z direction, and the direction perpendicular to the X and Z directions is the Y direction.