Optical Fiber Coupler Alignment via Collimation and Redirecting
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Solution Overview
Problem
Optical fiber coupler devices face stringent alignment tolerance specifications due to high light energy density at interfaces, leading to reduced production yields and signal quality issues, especially when using injection molding processes that can result in misalignment and deformation of guide posts.
Innovation Solution
The optical fiber coupler system includes a first lens module with collimating lenses to reduce light energy density and a second lens module with alignment features and an optical redirecting device, which together allow for lower misalignment tolerance specifications, enabling precise alignment and improved manufacturing yields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If focused optical light is used at the interface between lens modules, then optical signal transmission quality is improved, but alignment tolerance specification becomes more stringent
Solution Approach 1:
The patent introduces an intermediate optical element (such as a beam expander or diffuser) between the lens module and the optical fiber interface. This intermediary element redistributes the focused light energy over a larger area, reducing the peak light energy density at the interface while maintaining overall optical signal quality, thereby relaxing the alignment tolerance requirements
Solution Approach 2:
The patent changes the optical parameters (beam diameter, energy density distribution) by introducing additional optical elements that modify the light path. By expanding the beam size or diffusing the light before it reaches the fiber interface, the system maintains optical signal integrity while reducing the stringent alignment tolerance specification
2Productivity
If injection molding process is used for manufacturing, then production efficiency is improved, but misalignment and deformation of guide posts occurs
Solution Approach 1:
The patent divides the optical coupler system into separate functional modules (lens modules, guide post assemblies, fiber coupling sections) that can be manufactured independently using injection molding, then assembled together with precision alignment features. This segmentation allows mass production of individual components while maintaining overall assembly precision
Solution Approach 2:
The patent incorporates preliminary alignment features such as precision-machined reference surfaces, positioning pins, or pre-aligned guide posts that are manufactured separately and then assembled. This preliminary preparation of alignment features before final assembly enables the injection molding process to focus only on forming the components, while precision is achieved through the pre-prepared alignment structures
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 configuration reduces the stringent alignment requirements, enhances manufacturing efficiency, and ensures stable optical signal propagation by minimizing eccentricity between optical fibers and lenses, thereby improving production line quality control and signal transmission.
Implementation Method 1
one or more collimating lenses providing a first optical output having reduced optical light energy density as compared to optical light emerging from the emitting source
Implementation Method 2
a second lens array including one or more focusing lenses and an optical redirecting device providing a downstream second optical output
Implementation Method 3
an optical fiber cable integrally coupled to the second lens module to receive the second optical output
Data Source
AI summary
There is provided an optical coupler system. The system includes a first lens module including a first lens array positioned adjacent an emitting source. The first lens includes one or more collimating lenses. The system further includes a second lens module coupled to the first lens module. The second lens module may include alignment features. The system further includes a second lens array and an optical redirecting device providing a downstream second optical output, and an optical fibre cable integrally coupled to the second lens module.