Optical assembly and method for manufacture thereof

• US 20040013371A1
• Filed: 07/18/2002
• Published: 01/22/2004
• Est. Priority Date: 07/18/2002
• Status: Active Grant

• Current Assignee: AL Cielo Ltd.
• Original Assignee: Chiaro Networks, Ltd.
• Inventors: Rudman, Michael, Shekel, Eyal, Jeffrey, Levy
• Granted Patent: US 6,886,994 B2
• Time in Patent Office: Days
• US Class Current: 385/88
• CPC Class Codes: G02B 6/264 with optical elements between opposed fibre ends which perform a function other than beam splitting having lens focusing means G02B6/32; utilising prism or grating G02B6/34
• CPC Class Codes: G02B 6/4236 Fixing or mounting methods of the aligned elements
• CPC Class Codes: G02B 6/4237 Welding
• CPC Class Codes: G02B 6/4238 Soldering
• CPC Class Codes: G02B 6/4239 Adhesive bonding; Encapsulation with polymer material

Abstract

A method for accurately mounting an optical element in an optical assembly including precisely positioning the optical element in a desired position with respect to a reference surface, employing a non-metallic adhesive for initially fixing the optical element in the desired position and thereafter employing a metallic adhesive for permanently fixing the optical element in the desired position.

Claims

1. A method for accurately mounting an optical element in an optical assembly comprising

precisely positioning an optical element in a desired position with respect to a reference surface;

employing a non-metallic adhesive for initially fixing said optical element in said desired position; and

thereafter employing a metallic adhesive for permanently fixing said optical element in said desired position.

2. A method for accurately mounting an optical element according to claim 1 and wherein said precisely positioning comprises positioning said optical element in precise spaced relationship with respect to said reference surface.

3. A method for accurately mounting an optical element according to claim 2 and wherein said employing a non-metallic adhesive and thereafter employing a metallic adhesive comprise employing at least one side mounting element including at least one first surface which engages an edge of said optical element and at least one second surface which engages said reference surface.

4. A method for accurately mounting an optical element according to claim 3 and wherein at least one of said at least one first surface, said at least one second surface, said edge of said optical element and said reference surface includes separate metallic adhesive engagement and non-metallic adhesive engagement areas.

5. A method for accurately mounting an optical element according to claim 4 and wherein said separate metallic adhesive engagement and non-metallic adhesive engagement areas are separated by a groove.

6. A method for accurately mounting an optical element according to claim 3 and wherein each of said at least one first surface and said at least one second surface includes separate metallic adhesive engagement and non-metallic adhesive engagement areas.

7. A method for accurately mounting an optical element according to claim 6 and wherein said separate metallic adhesive engagement and non-metallic adhesive engagement areas are separated by a groove.

8. A method for accurately mounting an optical element according to claim 3 and wherein said at least one first surface includes separate metallic adhesive engagement and non-metallic adhesive engagement areas.

9. A method for accurately mounting an optical element according to claim 8 and wherein said separate metallic adhesive engagement and non-metallic adhesive engagement areas are separated by a groove.

10. A method for accurately mounting an optical element according to claim 8 and wherein said at least one second surface is permanently fixed to said reference surface by employing said metallic adhesive prior to employing said non-metallic adhesive for initially fixing said at least one first surface to said edge of said optical element.

11. A method for accurately mounting an optical element according to claim 3 and wherein said non-metallic adhesive is applied to at least one of said at least one first surface and said at least one second surface, said edge of said optical element being fixed to said reference surface prior to said precisely positioning of said optical element in said desired position with respect to said reference surface.

12. A method for accurately mounting an optical element according to claim 3 and wherein said metallic adhesive is applied to at least one of said at least one first surface and said at least one second surface, said edge of said optical element being fixed to said reference surface prior to said precisely positioning of said optical element in said desired position with respect to said reference surface.

13. A method for accurately mounting an optical element according to claim 1 and wherein said metallic adhesive is applied to at least one of said at least one first surface and said at least one second surface, said edge of said optical element being fixed to said reference surface prior to said precisely positioning of said optical element in said desired position with respect to said reference surface.

14. A method for accurately mounting an optical element according to claim 2 and wherein said employing a non-metallic adhesive and thereafter employing a metallic adhesive comprise mounting an edge of said optical element directly onto said reference surface.

15. A method for accurately mounting an optical element according to claim 14 and wherein at least one of said edge of said optical element and said reference surface includes separate metallic adhesive engagement and non-metallic adhesive engagement areas.

16. A method for accurately mounting an optical element according to claim 15 and wherein said separate metallic adhesive engagement and non-metallic adhesive engagement areas are separated by a groove.

17. A method for accurately mounting an optical element according to claim 14 and wherein each of said edge of said optical element and said reference surface includes separate metallic adhesive engagement and non-metallic adhesive engagement areas.

18. A method for accurately mounting an optical element according to claim 17 and wherein said separate metallic adhesive engagement and non-metallic adhesive engagement areas are separated by a groove.

19. A method for accurately mounting an optical element according to claim 14 and wherein said reference surface includes separate metallic adhesive engagement and non-metallic adhesive engagement areas.

20. A method for accurately mounting an optical element according to claim 19 and wherein said separate metallic adhesive engagement and non-metallic adhesive engagement areas are separated by a groove.

21. A method for accurately mounting an optical element according to claim 14 and wherein said non-metallic adhesive is applied to at least one of said edge of said optical element and said reference surface prior to said precisely positioning of said optical element in said desired position with respect to said reference surface.

22. A method for accurately mounting an optical element according to claim 21 and wherein said metallic adhesive is applied to at least one of said edge of said optical element and said reference surface prior to said precisely positioning of said optical element in said desired position with respect to said reference surface.

23. A method for accurately mounting an optical element according to claim 14 and wherein said metallic adhesive is applied to at least one of said edge of said optical element and said reference surface prior to said precisely positioning of said optical element in said desired position with respect to said reference surface.

24. A method for accurately mounting an optical element in an optical assembly comprising

precisely positioning said optical element in a desired position with respect to a reference surface,

employing a relatively low temperature curing adhesive for initially fixing said optical element in said desired position;

and

thereafter employing a relatively high temperature curing adhesive for permanently fixing said optical element in said desired position.

25. A method for accurately mounting an optical element according to claim 24 and wherein said precisely positioning comprises positioning said optical element in precise spaced relationship with respect to said reference surface.

26. A method for accurately mounting an optical element according to claim 25 and wherein said employing a low temperature adhesive and thereafter employing a high temperature adhesive comprise employing at least one side mounting element including at least one first surface which engages an edge of said optical element and at least one second surface which engages said reference surface.

27. A method for accurately mounting an optical element according to claim 26 and wherein at least one of said at least one first surface, said at least one second surface, said edge of said optical element and said reference surface includes separate high temperature adhesive engagement and low temperature adhesive engagement areas.

28. A method for accurately mounting an optical element according to claim 27 and wherein said separate high temperature adhesive engagement and low temperature adhesive engagement areas are separated by a groove.

29. A method for accurately mounting an optical element according to claim 26 and wherein each of said at least one first surface and said at least one second surface includes separate high temperature adhesive engagement and low temperature adhesive engagement areas.

30. A method for accurately mounting an optical element according to claim 29 and wherein said separate high temperature adhesive engagement and low temperature adhesive engagement areas are separated by a groove.

31. A method for accurately mounting an optical element according to claim 26 and wherein said at least one first surface includes separate high temperature adhesive engagement and low temperature adhesive engagement areas.

32. A method for accurately mounting an optical element according to claim 31 and wherein said separate high temperature adhesive engagement and low temperature adhesive engagement areas are separated by a groove.

33. A method for accurately mounting an optical element according to claim 31 and wherein said at least one second surface is permanently fixed to said reference surface by employing said high temperature adhesive prior to employing said low temperature adhesive for initially fixing said at least one first surface to said edge of said optical element.

34. A method for accurately mounting an optical element according to claim 26 and wherein said low temperature adhesive is applied to at least one of said at least one first surface and said at least one second surface, said edge of said optical element being fixed to said reference surface prior to said precisely positioning of said optical element in said desired position with respect to said reference surface.

35. A method for accurately mounting an optical element according to claim 26 and wherein said high temperature adhesive is applied to at least one of said at least one first surface and said at least one second surface, said edge of said optical element being fixed to said reference surface prior to said precisely positioning of said optical element in said desired position with respect to said reference surface.

36. A method for accurately mounting an optical element according to claim 34 and wherein said high temperature adhesive is applied to at least one of said at least one first surface and said at least one second surface, said edge of said optical element being fixed to said reference surface prior to said precisely positioning of said optical element in said desired position with respect to said reference surface.

37. A method for accurately mounting an optical element according to claim 25 and wherein said employing a low temperature adhesive and thereafter employing a high temperature adhesive comprise mounting an edge of said optical element directly onto said reference surface.

38. A method for accurately mounting an optical element according to claim 37 and wherein at least one of said edge of said optical element and said reference surface includes separate high temperature adhesive engagement and low temperature adhesive engagement areas.

39. A method for accurately mounting an optical element according to claim 38 and wherein said separate high temperature adhesive engagement and low temperature adhesive engagement areas are separated by a groove.

40. A method for accurately mounting an optical element according to claim 37 and wherein each of said edge of said optical element and said reference surface includes separate high temperature adhesive engagement and low temperature adhesive engagement areas.

41. A method for accurately mounting an optical element according to claim 40 and wherein said separate high temperature adhesive engagement and low temperature adhesive engagement areas are separated by a groove.

42. A method for accurately mounting an optical element according to claim 37 and wherein said reference surface includes separate high temperature adhesive engagement and low temperature adhesive engagement areas.

43. A method for accurately mounting an optical element according to claim 42 and wherein said separate high temperature adhesive engagement and low temperature adhesive engagement areas are separated by a groove.

44. A method for accurately mounting an optical element according to claim 37 and wherein said low temperature adhesive is applied to at least one of said edge of said optical element and said reference surface prior to said precisely positioning of said optical element in said desired position with respect to said reference surface.

45. A method for accurately mounting an optical element according to claim 44 and wherein said high temperature adhesive is applied to at least one of said edge of said optical element and said reference surface prior to said precisely positioning of said optical element in said desired position with respect to said reference surface.

46. A method for accurately mounting an optical element according to claim 37 and wherein said high temperature adhesive is applied to at least one of said edge of said optical element and said reference surface prior to said precisely positioning of said optical element in said desired position with respect to said reference surface.

47. A method for accurately mounting an optical element in an optical assembly comprising

precisely positioning said optical element in a desired position with respect to a reference surface,

employing a first curable adhesive for initially fixing said optical element in said desired position and

thereafter employing a second curable adhesive for fixing said optical element in said desired position.

48. A method for accurately mounting an optical element according to claim 47 and wherein said second adhesive is curable at a higher temperature than said first adhesive.

49. A method for accurately mounting an optical element according to claim 47 and wherein the curing process employed to cure said first adhesive applies less physical stress on said optical assembly than the curing process employed to cure said second adhesive.

50. A method for accurately mounting an optical element according to claim 47 and wherein the curing process employed to cure said first adhesive applies no appreciable physical stress on said optical assembly.

51. A method for accurately mounting an optical element according to claim 47 and wherein said second adhesive when cured provides a longer lasting bond than said first adhesive.

52. A method for accurately mounting an optical element according to claim 47 and wherein said first adhesive is a non-heat curable adhesive.

53. A method for accurately mounting an optical element according to claim 47 and wherein said second adhesive is a heat curable adhesive.

54. A method for accurately mounting an optical element according to claim 47 and wherein said first adhesive is a UV curable adhesive.

55. A method for accurately mounting an optical element according to claim 47 and wherein said second adhesive is a non-UV curable adhesive.

56. A method for accurately mounting an optical element according to claim 47 and wherein said precisely positioning comprises positioning said optical element in precise spaced relationship with respect to said reference surface.

57. A method for accurately mounting an optical element according to claim 56 and wherein said employing a first adhesive and thereafter employing a second adhesive comprise employing at least one side mounting element including at least one first surface which engages an edge of said optical element and at least one second surface which engages said reference surface.

58. A method for accurately mounting an optical element according to claim 57 and wherein at least one of said at least one first surface, said at least one second surface, said edge of said optical element and said reference surface includes separate first adhesive engagement and second adhesive engagement areas.

59. A method for accurately mounting an optical element according to claim 58 and wherein said separate first adhesive engagement and second adhesive engagement areas are separated by a groove.

60. A method for accurately mounting an optical element according to claim 57 and wherein each of said at least one first surface and said at least one second surface includes separate first adhesive engagement and second adhesive engagement areas.

61. A method for accurately mounting an optical element according to claim 60 and wherein said separate first adhesive engagement and second adhesive engagement areas are separated by a groove.

62. A method for accurately mounting an optical element according to claim 57 and wherein said at least one first surface includes separate first adhesive engagement and second adhesive engagement areas.

63. A method for accurately mounting an optical element according to claim 62 and wherein said separate first adhesive engagement and second adhesive engagement areas are separated by a groove.

64. A method for accurately mounting an optical element according to claim 62 and wherein said at least one second surface is permanently fixed to said reference surface by employing said second adhesive prior to employing said first adhesive for initially fixing said at least one first surface to said edge of said optical element.

65. A method for accurately mounting an optical element according to claim 57 and wherein said first adhesive is applied to at least one of said at least one first surface and said at least one second surface, said edge of said optical element being fixed to said reference surface prior to said precisely positioning of said optical element in said desired position with respect to said reference surface.

66. A method for accurately mounting an optical element according to claim 57 and wherein said second adhesive is applied to at least one of said at least one first surface and said at least one second surface, said edge of said optical element being fixed to said reference surface prior to said precisely positioning of said optical element in said desired position with respect to said reference surface.

67. A method for accurately mounting an optical element according to claim 65 and wherein said second adhesive is applied to at least one of said at least one first surface and said at least one second surface, said edge of said optical element being fixed to said reference surface prior to said precisely positioning of said optical element in said desired position with respect to said reference surface.

68. A method for accurately mounting an optical element according to claim 56 and wherein said employing a first adhesive and thereafter employing a second adhesive comprise mounting an edge of said optical element directly onto said reference surface.

69. A method for accurately mounting an optical element according to claim 68 and wherein at least one of said edge of said optical element and said reference surface includes separate first adhesive engagement and second adhesive engagement areas.

70. A method for accurately mounting an optical element according to claim 69 and wherein said separate first adhesive engagement and second adhesive engagement areas are separated by a groove.

71. A method for accurately mounting an optical element according to claim 68 and wherein each of said edge of said optical element and said reference surface includes separate first adhesive engagement and second adhesive engagement areas.

72. A method for accurately mounting an optical element according to claim 71 and wherein said separate first adhesive engagement and second adhesive engagement areas are separated by a groove.

73. A method for accurately mounting an optical element according to claim 68 and wherein said reference surface includes separate first adhesive engagement and second adhesive engagement areas.

74. A method for accurately mounting an optical element according to claim 73 and wherein said separate first adhesive engagement and second adhesive engagement areas are separated by a groove.

75. A method for accurately mounting an optical element according to claim 68 and wherein said first adhesive is applied to at least one of said edge of said optical element and said reference surface prior to said precisely positioning of said optical element in said desired position with respect to said reference surface.

76. A method for accurately mounting an optical element according to claim 75 and wherein said second adhesive is applied to at least one of said edge of said optical element and said reference surface prior to said precisely positioning of said optical element in said desired position with respect to said reference surface.

77. A method for accurately mounting an optical element according to claim 68 and wherein said second adhesive is applied to at least one of said edge of said optical element and said reference surface prior to said precisely positioning of said optical element in said desired position with respect to said reference surface.

78. A method for accurately mounting an optical element in an optical assembly comprising

precisely positioning said optical element in a desired position with respect to a reference surface,

employing an adhesive for fixing said optical element in said desired position including employing at least one side mounting element including at least one first surface which engages an edge of said optical element and at least one second surface which engages said reference surface,

wherein said at least one second surface is fixed to said reference surface prior to fixing said at least one first surface to said edge of said optical element.

79. A method for accurately mounting an optical element according to claim 78 and wherein said adhesive is applied to at least one of said at least one first surface and said at least one second surface, said edge of said optical element and said reference surface prior to said precisely positioning of said optical element in said desired position with respect to said reference surface.