Two-Photon Photopolymerized Vitreous Components for Optical Fiber Ends
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Solution Overview
Problem
Existing methods for assembling micro- or nano-structured optical and photonic components on optical fibers face challenges such as misalignment due to thermal shrinkage, delamination, and insufficient adhesion, especially in harsh environments, and polymer materials offer poor thermal stability and optical transmission.
Innovation Solution
A process involving a carrier made of vitreous material, assembled via multi-photon photopolymerization, with thermal annealing to transform the materials into vitreous form, followed by localized fusion to secure the assembly, ensuring accurate positioning and robust attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high-temperature annealing is performed to eliminate organic traces and produce silica glass, then the material transformation is achieved, but thermal shrinkage occurs causing misalignment and positioning errors
Solution Approach 1:
The carrier is pre-formed by multi-photon photopolymerization with dimensions deliberately enlarged compared to the final component. This preliminary action allows the subsequent thermal annealing to cause shrinkage that naturally brings the component to its correct final dimensions and position, eliminating positioning errors caused by shrinkage.
Solution Approach 2:
The patent changes the dimensional parameters of the carrier during the process. The carrier is initially created with larger dimensions through photopolymerization, then undergoes thermal annealing that reduces its dimensions to the correct size. This parameter change allows the component to be accurately positioned on the carrier before final assembly.
2Ease of manufacture
If polymer materials are used for micro-structured components, then manufacturing flexibility is improved, but thermal stability and optical transmission deteriorate
Solution Approach 1:
The patent uses composite materials consisting of a polymer matrix containing vitreous particles (such as silica). The polymer provides manufacturing flexibility and processability, while the vitreous particles provide thermal stability and optical properties. After thermal annealing, the composite transforms into a fully vitreous structure with superior properties.
Solution Approach 2:
The material undergoes a parameter change from a polymer-based composite to a fully vitreous structure through thermal annealing. This transformation occurs at controlled temperatures that first allow the component to be manufactured with polymer flexibility, then transform the material to achieve the required thermal stability and optical transmission.
3Ease of operation
If friction-based attachment is used between component and optical fibre, then assembly simplicity is improved, but connection strength deteriorates
Solution Approach 1:
The carrier acts as an intermediary element between the micro-structured component and the optical fibre. The component is first assembled on the carrier, which provides a stable platform. Then, the carrier is fused to the optical fibre, creating a strong permanent connection. This intermediary approach simplifies the overall assembly process while ensuring robust connection strength.
Solution Approach 2:
The patent replaces mechanical friction-based attachment with a fusion-based connection system. Instead of relying on friction between the component and fibre, the carrier is fused to the fibre through localized melting and bonding, creating a permanent, strong connection that is not dependent on mechanical friction.
4Stability of the object's composition
If thermal annealing is performed to transform material into vitreous form, then material stability is improved, but dimensional shrinkage occurs causing deformations and stresses
Solution Approach 1:
The carrier is pre-formed with dimensions that compensate for the upcoming thermal shrinkage. By deliberately creating the carrier with larger initial dimensions through photopolymerization, the subsequent thermal annealing that transforms the material to vitreous form results in the correct final dimensions, preventing deformations and stresses.
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 achieves a solid and accurately positioned assembly of micro- or nano-structured components on optical fibers, maintaining optical integrity and stability even in harsh conditions.
Implementation Method 1
making on a first end of said carrier, by multi-photon, in particular two-photon, photopolymerisation, a micro-structured or nano-structured component
Implementation Method 2
performing one or more heat treatment(s) so as to transform the first material of said carrier and the second material of said micro- or nano-structured component into a vitreous material
Implementation Method 3
assembling and securing a region of a second end of said carrier opposite to said first end with an area of one end or a lateral surface of said structure
Data Source
AI summary
A method of making of an optical device provided with a nano-structured or micro-structured component assembled on one end of an optical fibre includes providing a carrier based on a material photosensitive and transformable into a vitreous material, and making on a first end of the carrier, by two-photon photopolymerization, a micro-structured or nano-structured component, based on a material photosensitive and transformable into a vitreous material. The method also includes performing one or more heat treatment(s) so as to transform the material of the carrier and the material of the micro- or nano-structured component into a vitreous material and, then, assembling and securing a region of a second end of the carrier opposite to the first end with an area of an end of the optical fibre, by localised fusion of the region and the area, respectively of the carrier and the optical fibre.