Two-Part Optical Coupling Subassembly with Beam Router
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Solution Overview
Problem
Existing optical coupling systems for optical communication transceivers face challenges in maintaining coupling efficiency and alignment stability due to assembly process variations and temperature-induced refractive index changes, particularly in miniature designs with precise dimension constraints.
Innovation Solution
A two-part optical coupling subassembly with a main lens and a beam router embedded in its cavity, featuring oppositely inclined surfaces and a partially reflective coating, which provides self-correction of output beam angle and allows for greater assembly process variation and material selection, while maintaining optical alignment stability across temperature changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a two-part optical coupling system with beam splitter and focusing lens is used to achieve optical power monitoring and fiber coupling, then optical feedback function is achieved, but assembly process variation causes alignment instability and coupling efficiency variation
Solution Approach 1:
The optical coupling system is divided into two separate parts: a beam splitter component and a focusing lens component. Each part is independently manufactured and then assembled together, allowing for modular manufacturing and assembly while maintaining optical alignment through the integrated cavity design
Solution Approach 2:
The beam splitter component is positioned within a cavity formed in the focusing lens, creating a nested structure where one optical element is housed within another. This integration ensures precise relative positioning and maintains optical alignment while allowing independent manufacturing of each component
2Manufacturing precision
If precise injection molding with high-temperature thermoplastic is used to achieve dimension accuracy in miniature optical lens, then optical surface precision is improved, but material selection is limited and absorption may increase
Solution Approach 1:
The optical system separates the collimating lens and beam splitter into distinct components, allowing each to be optimized for its specific function and manufactured from materials best suited for that purpose, rather than requiring a single material to satisfy all requirements
Solution Approach 2:
The system allows selection of materials based on their optical properties at specific wavelengths, enabling optimization of refractive index, absorption characteristics, and thermal properties for each component based on its functional requirements
3Ease of manufacture
If a single-prism design combining beam splitting plate and wedge is used to simplify assembly, then assembly process is simplified, but optical alignment to output fiber remains sensitive to prism position in filler matrix
Solution Approach 1:
The optical system separates the beam splitting function and light focusing function into distinct components, allowing each to be independently optimized and positioned within the integrated cavity structure
Solution Approach 2:
The integrated cavity structure serves as an intermediary framework that precisely positions both the beam splitter and focusing lens relative to each other and to the optical fiber, eliminating sensitivity to positioning variations in filler materials
4Reliability
If shape matched beam splitting insert is assembled into lens cavity to reduce alignment variation, then fiber coupling efficiency variation is reduced, but assembly complexity increases
Solution Approach 1:
The beam splitter and focusing lens are merged into a single integrated optical assembly with a unified cavity structure, simplifying the overall assembly process while maintaining precise alignment through the integrated design
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 enhances optical coupling efficiency and reduces alignment shifts, allowing for more robust assembly processes and wider material choices, while maintaining stable optical alignment despite temperature-induced refractive index changes.
Implementation Method 1
a first collimating lens for collimating light from a vertical-cavity surface-emitting laser
Implementation Method 2
a second surface oriented at an angle with respect to the first surface for reflecting collimated light from the first collimating lens to an optical fiber
Implementation Method 3
a partially reflective coating provided on one of the first and second beam router surfaces... a portion of the collimated light is reflected by the partially reflective coating, decoupled from light transmitting towards the optical fiber, and directed to a light detector to monitor optical output power
Implementation Method 4
a transparent adhesive provided between the third surface and the first beam router surface, and between the fourth surface and the second beam router surface
Data Source
AI summary
A two-part optical coupling subassembly includes a main lens formed with a cavity, the main lens including two surfaces formed in the cavity and oppositely inclined at an off-vertical angle from a central vertical plane of the cavity such that the two surfaces are symmetric with respect to the central vertical plane; a beam router embedded in the cavity, the beam router including first and second beam router surfaces lying on the two surfaces of the main lens respectively, and a partially reflective coating on at least one of the beam router surfaces; and a transparent adhesive provided between the two lens surfaces and the first and second beam router surfaces.