Waveguide-Side Microlens Structure for Compact Beam Alignment
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Solution Overview
Problem
Optical waveguides require beam steering, which is challenging due to their small size, leading to increased overall size and difficulty in aligning beams for continuous transmission using current adapters.
Innovation Solution
A method to form microlenses directly at the light exit surface of optical waveguides, diverting light beams from a parallel to a downward direction by forming an optical lens groove, applying an anti-reflection layer, filling with an optical lens material, and shaping it through a reflow process to achieve a controlled curvature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an adapter is used to steer the beam, then beam steering is achieved, but the overall size increases and alignment becomes difficult
Solution Approach 1:
The microlens is integrated directly onto the waveguide surface, merging the beam steering function with the waveguide structure itself. This eliminates the need for separate adapters and reduces the overall device size while maintaining alignment precision.
Solution Approach 2:
The microlens redirects light from the waveguide's light exit surface downward into the optical lens groove, utilizing the vertical dimension for beam steering. This dimensional approach enables compact beam control without requiring lateral space for traditional adapters.
2Ease of operation
If an adapter is used for beam steering, then light direction is changed, but alignment precision deteriorates
Solution Approach 1:
By integrating the microlens directly with the waveguide, the invention eliminates alignment interfaces between separate components. This monolithic structure ensures precise and stable beam alignment for continuous transmission without the tolerance accumulation issues of assembled adapters.
3Volume of moving object
If microlens is formed directly on waveguide, then size is reduced, but manufacturing complexity increases
Solution Approach 1:
The reflow process utilizes temperature and time parameter control to transform the microlens preliminary structure into the final microlens. By adjusting heating parameters, the optical lens material self-organizes into the desired curved lens shape, enabling precise microlens fabrication without complex manufacturing steps.
4Manufacturing precision
If reflow process is used to form microlens, then curvature is controlled, but process complexity increases
Solution Approach 1:
The reflow process controls microlens curvature by varying temperature and time parameters. This single-process parameter control method achieves precise curvature adjustment without requiring multiple fabrication steps or complex equipment, balancing manufacturing precision with process simplicity.
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 small-size beam alignment and continuous transmission by directly forming microlenses on optical waveguides, reducing size and simplifying alignment processes.
Implementation Method 1
performing a reflow process on the microlens preliminary structure to form a microlens
Implementation Method 2
performing a reflow process on the microlens preliminary structure to form a microlens
Implementation Method 3
forming an anti-reflection layer to cover the optical waveguide block and the optical lens groove
Data Source
AI summary
The present invention relates to a preparation method and structure of multi-layer stacked waveguide. The method involves providing an optical waveguide block; forming an optical lens groove in the optical waveguide block; forming an anti-reflection layer to cover the optical waveguide block and the optical lens groove; forming an optical lens material above the optical waveguide block and filling the optical lens groove; removing portions of the anti-reflective layer and the optical lens material to define a preliminary microlens structure; and performing a reflow process on the preliminary microlens structure to form a microlens.