Optical Isolator Base Member Segmentation for Alignment
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Solution Overview
Problem
Existing optical isolator manufacturing methods often result in misalignment of optical components, leading to suboptimal optical characteristics due to inaccurate positioning and adhesive issues.
Innovation Solution
The optical isolator is designed with a base member that includes specific holding surfaces and index marks to accurately position and adhere optical components, using elastic adhesive to prevent stress and ensure high adhesion strength and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is used to fix optical components on substrate, then components are held in place, but alignment accuracy deteriorates due to adhesive overflow and positioning difficulty
Solution Approach 1:
The base member is divided into distinct functional regions: a positioning protrusion for precise angular alignment, a flat holding surface for stable placement, and a separate adhesive application area. This segmentation allows each region to perform its specific function without interfering with others, ensuring both accuracy and reliability
Solution Approach 2:
The positioning protrusion and flat holding surface are pre-formed on the base member before adhesive application. This preliminary positioning structure ensures that optical components are correctly aligned and secured before the adhesive is applied, preventing misalignment that would occur with adhesive-only fixation
2Strength
If adhesive is applied to hold optical components, then components are securely attached, but optical characteristics deteriorate due to adhesive contamination of optical surfaces
Solution Approach 1:
The adhesive application area is extracted and separated from the optical surfaces of the component. Adhesive is applied only to the side surface and bottom surface of the optical component, excluding the optical surfaces from the adhesive bonding process, thus preventing contamination while maintaining secure attachment
Solution Approach 2:
Different surfaces of the optical component are treated differently: the side surface and bottom surface receive adhesive for bonding, while the optical surfaces remain free of adhesive to maintain their optical properties. This localized adhesive application ensures both strong bonding and optical performance
3Ease of manufacture
If conventional adhesive fixation is used, then components are attached to substrate, but positioning accuracy deteriorates due to lack of precise positioning structures
Solution Approach 1:
The base member is segmented into distinct functional zones: a positioning protrusion for angular alignment, a flat holding surface for positional stability, and an adhesive application zone. This segmentation provides precise positioning guidance while maintaining a simple overall manufacturing process
Solution Approach 2:
The positioning protrusion acts as an intermediary element between the base member and the optical component, providing precise angular positioning. The flat holding surface serves as an intermediary that ensures stable placement, simplifying the attachment process while achieving high positioning accuracy
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 ensures optical components are accurately aligned and securely attached, maintaining optical characteristics and preventing adhesive contamination, thereby enhancing the reliability and performance of the optical isolator.
Implementation Method 1
a second surface of the optical component is adhesively attached to a second holding surface of the base member with the adhesive interposed therebetween
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3
AI summary
An optical device of the invention includes: a plurality of optical components arranged along a first direction, each optical component having an optical surface, a first surface intersecting with the optical surface, and a second surface intersecting with the optical surface and the first surface; and a base member that integrally holds the plurality of the optical components and has a first holding surface and a second holding surface, the first holding surface holding the optical components and fixing positions of the optical components in a second direction intersecting with the first direction in a state of being in contact with the optical components on the first surface, the second holding surface holding the second surface of the optical components with an adhesive interposed therebetween and fixing positions of the optical components in a third direction intersecting with the first direction and the second direction.