Optical Wire Manufacturing with Image-Guided UV Curing
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Solution Overview
Problem
The challenge in photonic chip packaging is achieving precise optical alignment, which is costly and difficult for mass production due to the need for highly precise design and minute chip/optical fiber arrangement technology.
Innovation Solution
An apparatus and method for manufacturing an optical wire that includes a wire forming module to create the optical wire, an image acquisition module to inspect the wire's shape and position, and a curing module to apply UV light for curing, all controlled by a module that ensures accurate alignment and curing without active alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If precise optical alignment is performed using traditional methods with lenses and prisms, then optical coupling efficiency is improved, but manufacturing cost increases and mass production becomes difficult
Solution Approach 1:
The patent extracts and removes the complex alignment components (lenses and prisms) from the optical coupling system, replacing them with a simplified optical wire structure that achieves coupling without requiring precise active alignment, thereby reducing manufacturing cost and enabling mass production while maintaining coupling efficiency
Solution Approach 2:
The patent introduces an optical wire as an intermediary element between photonic chips, which serves as a flexible connection medium that can accommodate alignment variations, eliminating the need for complex lens-prism alignment mechanisms and enabling easier manufacturing
2Measurement precision
If active alignment technology is used to achieve precise optical alignment, then alignment precision is improved, but device complexity increases
Solution Approach 1:
The optical wire structure is designed to self-align and accommodate position variations inherently through its flexible geometry, eliminating the need for complex active alignment systems and sophisticated chip arrangement technologies while maintaining precise optical coupling
3Adaptability or versatility
If the optical wire is formed without immediate curing, then shape adjustment flexibility is improved, but shape deformation occurs
Solution Approach 1:
The patent applies preliminary curing action at controlled stages during optical wire formation - initially forming the wire in an uncured flexible state for positioning, then applying UV light to cure and fix the shape, preventing deformation while maintaining the flexibility needed for precise shape adjustment during the formation process
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 allows for the efficient manufacturing of optical wires with precise alignment and shape control, reducing production costs and enabling mass production by eliminating the need for active alignment and minimizing shape deformation.
Implementation Method 1
outputs a control signal to the curing module so that ultraviolet (UV) light is emitted to the optical wire
Implementation Method 2
an optical filter configured to reflect or transmit light incident on the camera through the first spatial portion and reflect or transmit light emitted from the light source
Implementation Method 3
an optical filter configured to reflect or transmit light incident on the camera through the first spatial portion and reflect or transmit light emitted from the light source
Data Source
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AI summary
Provided are an apparatus and method for manufacturing an optical wire. The apparatus includes a wire forming module configured to form an optical wire for optically coupling a first point to a second point, an image acquisition module configured to acquire an image of the optical wire, a curing module configured to cure the optical wire, and a control module. The control module checks a shape and position of the optical wire through the image acquired by the image acquisition module and outputs a control signal to the curing module so that ultraviolet (UV) light is emitted to the optical wire.