Optical waveguides – With optical coupler – Input/output coupler
Reexamination Certificate
2001-04-30
2003-07-01
Feild, Lynn D. (Department: 2839)
Optical waveguides
With optical coupler
Input/output coupler
C385S080000
Reexamination Certificate
active
06587618
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to a method and system for aligning optical fibers to a lens array, and relates particularly to, a method and system for aligning optical fibers to a lens array in which each fiber is aligned at the focal point of a different lens of the array and then attached to the array, such that beams emitted from lenses of the array are pointing in the same direction, i.e., parallel to each other, when light is provided to their respective fibers. The invention further relates to a collimator array provided by the assembly of the lens array and such aligned optical fibers.
BACKGROUND OF THE INVENTION
In the fabrication of optical devices, it is often desirable to produce a set of collimated optical signals (e.g., beams), each encoded with information from a different source. Monolithic one or two-dimensional arrays of collimating elements may be used in which each collimating element is coupled to a different optical path (e.g. an optical fiber) to provide this set of collimated optical signals. Such a lens array, referred to as a microlens array herein, may consist of a plurality of lens elements formed into a single substrate, or plate, of material, or integrated onto such substrate. This material may be, for example, of plastic (polymers), glass, silicon, or silica. Each optical fiber is attached to the back surface of the substrate for illuminating a different one of the lenses in the array. The end of each optical fiber should be aligned at the focal point of its respective lens to enable optimal light beam collimation, focusing, or maximum light coupling (minimum insertion loss) into another similarly produced lens. Moreover, such alignment should provide collimated beams aligned parallel to each other from lenses when light is provided to their respective fibers. Positioning the optical fibers so that the optical beams emerging from the collimator array are highly collimated and collimated parallel to each other is a difficult task, becoming even more difficult with increased density of lens in the array.
One possible method of alignment is to use a complex structure of a matrix of optical fibers which may be provided by threading optical fibers into holes of a substrate and then polish the ends of the fibers to be aligned to the array. The complex structure is oriented and attached to the lenses of the array to couple illumination from fibers to lenses of the array. This however does not assure that the ends of the fibers are each properly located at the focal point of each lens, or that one of more of the ends of the fibers are not tilted to effect orientation of beams from lenses.
The complex structure for fiber alignment may be fabricated into one side of the substrate containing the microlens array. For example, U.S. Pat. No. 5,346,583 describes a method for aligning optical fibers with a microlens array in which one side of a substrate contains the microlens array and the other side has an array of circular apertures each aligned with the central axis of one of the lenses of the array. Optical fibers are inserted into these apertures, such that the ends of the fibers are aligned in a common plane with respect to the lenses. The substrates' sides are produced by a photolithographic mask and etching processes on each side of the substrate. This method thus requires two masks, which must be precisely aligned with each other, otherwise the central axis of the lenses will not align with the circular apertures. Laser beams are directed through a slot in each mask for mask-to-mask alignment. This may improve enmasse alignment of optical fibers, but such manufacture increases the cost of the microlens array, and does not account for variations which often occur in the focal length between different microlenses of the array. Thus, it would be desirable to align multiple fibers to a microlens array, without requiring a complex structure for enmasse fiber alignment.
In fiber optic connections, techniques have been developed for aligning an individual optical fiber to a GRIN (graduated refractive index) lens. For example, in U.S. Pat. Nos. 4,509,827 and 4,545,643, a mirrored surface is positioned substantially orthogonal relative to the axis of a GRIN lens to autocollimate a light beam transmitted through a fiber. The fiber is positioned relative to the lens such that the returned signals from the mirrored surface is maximized. An adhesive then secures the fiber to the lens. In a further example of fiber optics connection, U.S. Pat. No. 4,637,683 aligns an optical fiber to a GRIN lens having a reflective surface coating on the side of the lens opposite from the fiber, where the reflective surface provides a reference plane. The optical fiber is positioned relative to the GRIN lens to maximize the reflected light from the reference plane. Such methods of U.S. Pat. Nos. 4,509,827, 4,545,643 and 4,637,683 are limited to alignment of a single fiber to a single GRIN lens rather than alignment of multiple optical fibers to a microlens array.
Other alignment methods for aligning an individual fiber to a lens use transmitted, rather than reflected light. U.S. Pat. No. 5,009,482, describes joining an optical fiber with a spherical lens by detecting the amount of light transmitted by the lens into the fiber, and iteratively positioning the fiber relative to the lens to maximize the amount of detected light. In European Pat. Publication EP 0619505B1, multiple separate GRIN lens are aligned with optical fibers in a structure mechanically providing an optical collimator array. Light is passed along the optical fibers and beams emitted from the GRIN lenses are imaged on a CCD camera and shown on a monitor coupled to the CCD camera. The centers of the beams in the image are used to adjust the position of fibers and lens to provide the desired output from the optical collimation array.
Often optical fiber have a ferrule coupled about one of their ends having a front surface planar with the end of the fiber to be attached to a microlens array. In attaching individual fibers to the array, excess adhesive used in joining the fiber to the array protrudes from the location where the ferrule attaches to the back surface of the lens array's substrate. Often such protruding adhesive forms a bead or runs along the back surface of the array's substrate. This can be a problem since the protruding adhesive can interfere with attachment of other neighboring fibers to the array. Thus, it would be desirable to avoid protruding adhesive in the attachment of fibers to the microlens array.
SUMMARY OF THE INVENTION
Accordingly, it is the principal object of the present invention to provide an improved method and system for aligning optical fibers to a lens array in which each fiber is aligned to a different lens to obtain proper collimation, focusing, or maximum light coupling, without enmasse alignment techniques of the prior art.
It is another object of the present invention to provide an improved method and system for aligning optical fibers to a lens array to obtain optical signals or beams aligned parallel to each other from lenses of the array when respective fibers receive illumination providing such optical signals.
A further object of the present invention is to provide an improved method and system for aligning optical fibers to a lens array in which alignment can be performed either manually, or automatically by a programmed computer.
A still further object of the present invention is to provide an improved method and system for aligning optical fibers to a lens array which avoid excessive adhesive used in joining fibers to the lens array from protruding upon the back surface of the lens array and interfering with attachment of other neighboring fibers to the array.
Briefly described, the present invention embodies a method for aligning optical fibers to a lens array in which the lens array has a substrate with a front surface providing a plurality of lenses in the array, and a back surface for input (or output) of light for the lenses. The
Chakmakjian Steve
Farmiga Nestor
Raguin Daniel H.
Tiberio Theodore J.
Ward Bradley J.
Bean Gregory V.
Feild Lynn D.
Hyeon Hae Moon
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