Optical Fiber–Microlens Alignment with Tilt and Position Sensing
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Solution Overview
Problem
Existing methods for aligning optical fibers with microlens arrays and measuring cleave angles are inadequate, failing to account for manufacturing variations and tight alignment tolerances, leading to inefficiencies and potential damage during the alignment process.
Innovation Solution
The use of an MLA alignment system with tilt and position sensing devices, along with a beam splitter and collecting lens, to actively align optical fibers with microlens arrays, and a cleave angle measurement system with an optical fiber channel and image sensor to accurately measure cleave angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional alignment methods are used for optical fibers with microlens arrays, then the alignment process is simple, but the alignment precision is insufficient and may cause fiber damage
Solution Approach 1:
The patent replaces traditional mechanical alignment methods with an optical-based alignment system that uses light beams, position sensing devices, and tilt sensing devices to detect and measure fiber position and orientation, thereby achieving higher precision without relying on mechanical contact that could damage the fiber
Solution Approach 2:
The patent introduces an optical beam as an intermediary between the optical fiber and the sensing devices. The light beam carries information about the fiber's position and tilt angle to the position sensing device and tilt sensing device, enabling non-contact measurement and alignment
2Measurement precision
If traditional cleave angle measurement methods are used, then the measurement process is simple, but the measurement precision is insufficient
Solution Approach 1:
The patent replaces traditional mechanical or visual cleave angle measurement methods with an optical measurement system that uses a position sensing device to detect the position of reflected light from the fiber end face, calculating the cleave angle with high precision through optical means
Solution Approach 2:
The patent employs a feedback mechanism where the position sensing device continuously monitors the light beam position, and the system adjusts the fiber position based on the measured deviations, iteratively improving measurement accuracy and enabling precise alignment
3Reliability
If alignment tolerances are made tighter to improve bonding quality, then the bonding quality improves, but the alignment difficulty increases and process time increases
Solution Approach 1:
The patent uses real-time feedback from position sensing devices to monitor alignment status and automatically adjust fiber position, enabling the system to achieve tight alignment tolerances efficiently without manual intervention or repeated adjustments
Solution Approach 2:
The patent performs preliminary measurement of the fiber's initial position and tilt angle using the position sensing device and tilt sensing device before bonding, allowing the system to pre-calculate the required adjustments and achieve precise alignment in a single positioning action
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
Enables precise alignment of optical fibers with microlens arrays and accurate measurement of cleave angles, improving efficiency and reducing damage during the alignment process.
Implementation Method 1
optical fibers have structures that support propagation of light by way of total internal reflection
Implementation Method 2
transmitting a first portion of the light beam from the first end of the optical fiber through the beam splitter before reaching the position sensing device and reflecting a second portion of the light beam from the first end of the optical fiber off of the beam splitter
Data Source
AI summary
Systems and methods for aligning an optical fiber are provided herein. The method may include providing an optical fiber having a first end and a second end, where the first end of the optical fiber has a predefined manufacturing property. For example, the predefined manufacturing property of the first end of the optical fiber may include a predefined cleave angle. The method may also include positioning the optical fiber such that the first end of the optical fiber faces a microlens array (MLA) alignment system. In an example embodiment, the MLA alignment system may include a tilt sensing device and a position sensing device. The method may also include emitting a light beam from the first end of the optical fiber toward the MLA alignment system.