Optical Device Stepped End Face Alignment
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Solution Overview
Problem
Existing optical devices face challenges in minimizing optical coupling loss between optical waveguides and optical fibers, particularly due to warping of lapping blades during the polishing process, which prevents optimal alignment and proximity of the optical surfaces.
Innovation Solution
The optical device employs an optical element with a first end face and a second end face protruding from the first, optically coupled to an optical fiber block with a third end face and a fourth end face recessed from the third. This configuration allows for precise alignment and contact between the optical surfaces, reducing optical coupling loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If lapping blade is used for polishing the cut surface, then lead time is shortened, but blade warping occurs causing increased optical coupling loss
Solution Approach 1:
The optical element is divided into two separate components: a first optical element with a protruding second end face and a second optical element with a recessed fourth end face. This segmentation allows each component to be processed independently with standard lapping blades, avoiding blade warping while maintaining the optical coupling benefits of the stepped configuration.
Solution Approach 2:
The protruding second end face of the first optical element and the recessed fourth end face of the second optical element act as intermediary mechanical reference surfaces. These stepped interfaces provide stable contact points for alignment and fixation, enabling precise optical surface alignment without requiring the lapping blade to maintain its shape during polishing.
2Loss of energy
If optical polishing is performed on cut surfaces, then optical coupling loss is reduced, but processing cost and lead time increase
Solution Approach 1:
Optical polishing is applied selectively only to the first end face and third end face that require high optical quality, while the second and fourth end faces are processed by standard lapping. This local differentiation reduces overall processing time and cost while maintaining low optical coupling loss through the stepped mechanical alignment provided by the protruding and recessed surfaces.
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
This approach effectively suppresses optical coupling loss between the optical waveguide and the optical fiber, achieving a reduction of approximately 0.62 dB compared to traditional methods, while also shortening the lead time and reducing costs associated with complex polishing processes.
Implementation Method 1
The end face 113A of the optical waveguide 113 and the core end face 121B1 are optically coupled by a butt-joint using an optical adhesive A that is transparent in the optical communication wavelength range.
Data Source
AI summary
An optical device includes an optical element and an optical fiber block. The optical element includes an optical waveguide, a first end face on which an end face of the optical waveguide is disposed, and a second end face protruding from the first end face. The optical fiber block includes an optical fiber, a third end face on which an end face of the optical fiber is disposed, and a fourth end face recessed from the third end face. In the optical device, in a state where the second end face and the fourth end face are fixed so as to be in contact with each other, the first end face and the third end face are connected by butt coupling to optically couple the end face of the optical waveguide and the end face of the optical fiber.