Precision TFF POSA Flat Surface and Parallel Fiber Alignment
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Solution Overview
Problem
Conventional thin-film filter (TFF) passive optical system assemblies (POSAs) used in wavelength-division multiplexing (WDM) applications face challenges due to the curvature of TFF members caused by thermal expansion mismatch, leading to optical path deviations and inefficient optical coupling in WDM systems.
Innovation Solution
A precision TFF POSA is formed by pressing a TFF glass rod array into a master glass block to flatten the TFFs, using a securing material to reduce curvature, and singulating the structure to create TFF members with flat surfaces, along with positionally adjustable fiber interface devices for optimal optical communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional TFF deposition processes are used on glass substrates, then TFF members can be formed, but thermal expansion mismatch causes curvature in the TFF surfaces leading to optical path deviations
Solution Approach 1:
The patent applies preliminary action by pre-flattening the TFF surfaces through a pressing process before the TFF members are fully integrated into the optical system. The pressing apparatus applies controlled force to the curved TFF surfaces to flatten them prior to use, preventing optical path deviations without requiring changes to the deposition process itself.
2Productivity
If TFF members with curved surfaces are used in WDM systems, then the system can be assembled, but optical path deviations occur reducing coupling efficiency
Solution Approach 1:
The patent changes the physical parameter of the TFF surface from curved to flat by applying mechanical pressing force. This parameter change eliminates optical path deviations and improves coupling efficiency while maintaining system assembly capability. The pressing process transforms the surface geometry to achieve both assembly productivity and optical reliability.
3Manufacturing precision
If positionally adjustable fiber interface devices are implemented, then precise alignment for optimal optical communication is achieved, but device complexity increases
Solution Approach 1:
The patent implements dynamics by making the fiber interface devices positionally adjustable rather than fixed. This allows precise alignment optimization for each device while maintaining a relatively simple overall structure. The adjustability enables fine-tuning of optical paths without requiring complex rigid positioning mechanisms.
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 method significantly reduces optical path deviations, enabling reliable and efficient optical coupling in WDM systems by ensuring flat TFF surfaces and allowing for precise alignment of photonic devices, thereby improving the performance of WDM systems.
Implementation Method 1
Each TFF member 30 is configured to transmit one of the wavelength components and reflect the others
Implementation Method 2
The reflective coating 25 thereon reflects the light beam 90′ toward the next TFF member 30b
Data Source
AI summary
The precision TFF POSA is formed by pressing a TFF glass rod array into a top surface of a master glass block to flatten the otherwise curved TFFs formed using conventional TFF deposition processes on glass. The TFF glass rod array is secured to the master glass block with a securing material to form a fabrication structure, which is singulated to form precision TFF POSAs having TFF members with flat TFFs and long TFF member long axes. A fiber interface device is arranged at a back surface of the TFF POSA. Other fiber interface devices having device axes are arranged proximate the TFF members. The device axes are parallel to the TFF member long axes to form a WDM system with a parallel configuration. In this configuration, there is one positionally adjustable fiber interface device for each wavelength channel, which allows for optimizing WDM optical communication in Mux and DeMux directions.