Passive Lens Array Structure for PIC Fiber Alignment
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Solution Overview
Problem
Optical coupling systems require precise alignment, which is resource-intensive and costly, especially in large systems, and existing solutions are not suitable for high-temperature applications or mechanical stress reduction.
Innovation Solution
A micro lens array (MLA) with glass substrate and blind holes, fabricated using laser direct writing, allows for passive alignment and mechanical support of optical fibers, using glass and epoxy materials compatible with high-temperature processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If active alignment process is used to achieve precise fiber alignment, then alignment precision is improved, but assembly time and cost increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-aligning the optical fibers to the lens array using a passive alignment method before final assembly. The fibers are positioned in relation to the lenses through mechanical features (such as V-grooves or registration marks) that establish alignment without requiring optical measurement or adjustment during assembly. This preliminary mechanical alignment eliminates the need for time-consuming active alignment processes, thereby improving assembly throughput while maintaining sufficient alignment precision for optical coupling.
2Manufacturing precision
If traditional alignment methods are used, then alignment accuracy is achieved, but resource consumption and assembly cost increase
Solution Approach 1:
The patent implements self-service alignment through self-aligning mechanical features integrated into the lens array structure. The lens array includes features such as V-grooves, registration marks, or mechanical stops that automatically guide and position the optical fibers into correct alignment during assembly. This self-aligning mechanism eliminates the need for operator intervention or complex alignment equipment, reducing both assembly time and resource consumption while maintaining alignment accuracy through the geometric constraints of the mechanical features.
3Reliability
If conventional optical coupling structures are used, then optical coupling is achieved, but mechanical stress on fibers increases
Solution Approach 1:
The patent applies segmentation by separating the optical coupling function from the mechanical support function into distinct structural elements. The lens array is divided into independent lens elements mounted on a substrate, with dedicated mechanical features (such as separate V-grooves or support structures) that provide fiber positioning without applying stress to the fibers. This segmentation allows the optical path to be established through the lens elements while the mechanical support structure provides stress-free positioning, thereby maintaining both optical coupling reliability and fiber mechanical strength.
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 cost-effective, high-throughput assembly with reduced mechanical stress, compatible with reflow processes, and improved optical coupling efficiency.
Implementation Method 1
fabricated using laser direct writing
Implementation Method 2
a lens on the second surface of the substrate, wherein a first axial centerline of the hole is substantially coincident with a second axial centerline of the lens
Data Source
AI summary
An embodiment may include an apparatus comprising a substrate with a thickness between a first surface and a second surface, where the substrate comprises a glass layer and a hole into the first surface of the substrate and into the glass layer. In an embodiment, a depth of the hole is less than the thickness, and a lens is on the second surface of the substrate, where a first axial centerline of the hole is substantially coincident with a second axial centerline of the lens.