Optical device with alignment compensation

• US 20040212802A1
• Filed: 04/22/2003
• Published: 10/28/2004
• Est. Priority Date: 02/20/2001
• Status: Abandoned Application

• Current Assignee: CyberOptics Corporation (Nordson Corporation)
• Original Assignee: CyberOptics Corporation (Nordson Corporation)
• Inventors: Case, Steven K., Skunes, Timothy A., Knipfer, Michael, Mowry, Gregory S.
• Application Number:
  US10/420,349
• Publication Number:
  US 20040212802A1
• Time in Patent Office: Days
• US Class Current: 356/401
• CPC Class Codes: G02B 26/0875 by means of one or more refracting elements
• CPC Class Codes: G02B 6/255 Splicing of light guides, e.g. by fusion or bonding
• CPC Class Codes: G02B 6/2553 Splicing machines, e.g. optical fibre fusion splicer
• CPC Class Codes: G02B 6/2555 Alignment or adjustment devices for aligning prior to splicing
• CPC Class Codes: G02B 6/29365 in a multireflection configuration, i.e. beam following a zigzag path between filters or filtering operations
• CPC Class Codes: G02B 6/2938 for multiplexing or demultiplexing, i.e. combining or separating wavelengths, e.g. 1xN, NxM
• CPC Class Codes: G02B 6/32 having lens focusing means positioned between opposed fibre ends with lens being an integral part of the single fibre end G02B6/262
• CPC Class Codes: G02B 6/3636 the mechanical coupling means being grooves G02B6/3652 takes precedence
• CPC Class Codes: G02B 6/3652 the additional structures being prepositioning mounting areas, allowing only movement in one dimension, e.g. grooves, trenches or vias in the microbench surface, i.e. self aligning supporting carriers
• CPC Class Codes: G02B 6/3838 using grooves for light guides
• CPC Class Codes: G02B 6/3873 Connectors using guide surfaces for aligning ferrule ends, e.g. tubes, sleeves, V-grooves, rods, pins, balls
• CPC Class Codes: G02B 6/4204 the coupling comprising intermediate optical elements, e.g. lenses, holograms encapsulated active devices H01S5/02208, H01L33/52
• CPC Class Codes: G02B 6/4206 Optical features G02B6/4207, G02B6/421 take precedence
• CPC Class Codes: G02B 6/4207 with optical elements reducing the sensitivity to optical feedback anti-reflection devices specially adapted for lasers, see H01S3/0064
• CPC Class Codes: G02B 6/4221 involving a visual detection of the position of the elements, e.g. by using a microscope or a camera
• CPC Class Codes: G02B 6/4224 using visual alignment markings, e.g. index methods
• CPC Class Codes: G02B 6/4225 by a direct measurement of the degree of coupling, e.g. the amount of light power coupled to the fibre or the opto-electronic element
• CPC Class Codes: G02B 6/4226 Positioning means for moving the elements into alignment, e.g. alignment screws, deformation of the mount
• CPC Class Codes: G02B 6/4227 Active alignment methods, e.g. procedures and algorithms
• CPC Class Codes: G02B 6/4228 Passive alignment, i.e. without a detection of the degree of coupling or the position of the elements G02B6/4234 takes precedence
• CPC Class Codes: G02B 6/423 : using guiding surfaces for the alignment
• CPC Class Codes: G02B 6/4231 : with intermediate elements, e.g. rods and balls, between the elements
• CPC Class Codes: G02B 6/4232 : using the surface tension of fluid solder to align the elements, e.g. solder bump techniques flip-chip mounting techniques in assembly of semiconductor devices H01L24/81
• CPC Class Codes: G02B 6/4236 : Fixing or mounting methods of the aligned elements
• CPC Class Codes: G02B 6/4238 : Soldering
• CPC Class Codes: G02B 6/4239 : Adhesive bonding; Encapsulation with polymer material
• CPC Class Codes: G02B 7/003 : Alignment of optical elements G02B7/001, G02B7/002 take precedence; for mirrors G02B7/1822

Abstract

An optical device is provided which includes a plurality of optical modules and an alignment compensation module. Each optical module includes an optical component fixedly coupled to a relative reference mount. The relative reference mount is configured to attach to a substrate. A plurality of optical modules mount on the substrate to form the optical device. The alignment compensation module removes residual alignment errors of the optical device.

Claims

1. An optical device, comprising:

a substrate having a first registration feature and a second registration feature;

a first optical module comprising;

an optical component;

a relative reference mount including a registration feature configured to align with the first registration feature of the substrate, the optical component held at a prealigned spacial orientation relative to the registration feature;

a second optical module, comprising;

an optical component; and

a relative reference mount including a registration feature configured to align with the second registration feature of the substrate, the optical component held at a prealigned spacial orientation relative to the registration feature; and

the first and second optical modules arranged to transfer light therebetween.

an alignment compensation module configured to interact with the light to provide a final alignment to the light to thereby compensate for residual alignment errors.

5. The apparatus of claim 1 wherein the light beam is collimated.

6. The apparatus of claim 1 wherein the light is substantially converging.

7. The apparatus of claim 1 wherein the light is substantially diverging.

8. The apparatus of claim 1 wherein the alignment compensation module includes a lens element.

9. The apparatus of claim 1 wherein the alignment compensation module includes a lens element which is translated substantially perpendicular to a Z axis to adjust light beam alignment.

10. The apparatus of claim 9 including a lever arm alignment structure to translate the lens element.

11. The apparatus of claim 1 wherein the alignment compensation module includes an optical element with substantially two planar surfaces.

12. The apparatus of claim 11 wherein the optical element is rotated to provide the final alignment.

13. The apparatus of claim 1 wherein the alignment compensation module includes an afocal optical system configured to alter an angular propagation direction of the light.

14. The apparatus of claim 13 including an adjustable mount configured to rotate the afocal optical system.

15. The apparatus of claim 1 wherein at least one optical element has an optical characteristic which varies relative to at least one dimension and wherein the optical characteristic is aligned with a reference defined relative to a registration feature of the respective relative reference mount.

16. The apparatus of claim 1 wherein the optical device is a fiber optical demultiplexer.

2. An optical alignment compensation module to align a substantially collimated light beam with an initial angular propagation direction along a Z axis comprising:

an afocal optical system configured to deviate the angular propagation direction of the light beam when rotated about a Y axis perpendicular to the initial angular propagation (Z axis) direction, the amount of deviation less than the amount of rotation of the afocal optical system; and

a mount configured to rotate the afocal optical system about the Y axis perpendicular to the initial angular propagation direction (Z axis).

17. The apparatus of claim 2 wherein the alignment compensation module includes a lens element.

18. The apparatus of claim 2 wherein the mount includes a spherical surface and a receptacle.

19. The apparatus of claim 2 wherein the mount is fixedly secured with an attachment material.

3. A method of making an optical device comprising:

obtaining prealigned optical modules having registration features;

obtaining a fixed reference with registration features configured to mate with the registration features of the prealigned optical modules;

mounting the optical modules onto the fixed reference and aligning the registration features;

obtaining an alignment compensation module; and

adjusting a path of light through the optical device with the alignment compensation module.

20. The method of claim 3 wherein the light beam is collimated.

21. The method of claim 3 wherein the light is substantially converging.

22. The method of claim 3 wherein the light is substantially diverging.

23. The method of claim 3 wherein the alignment compensation module includes a lens element.

24. The method of claim 3 wherein the alignment compensation module includes a lens element which is translated substantially perpendicular to a Z axis to adjust light beam alignment.

25. The method of claim 24 including a lever arm alignment structure to translate the lens element.

26. The method of claim 3 wherein the alignment compensation module includes an optical element with substantially two planar surfaces.

27. The method of claim 26 wherein the optical element is rotated to provide the final alignment.

28. The method of claim 3 wherein the alignment compensation module includes an afocal optical system configured to alter an angular propagation direction of the light.

29. The method of claim 28 including an adjustable mount configured to rotate the afocal optical system.

30. The method of claim 3 wherein at least one optical element has an optical characteristic which varies relative to at least one dimension and wherein the optical characteristic is aligned with a reference defined relative to a registration feature of the respective relative reference mount.

4. A method of compensating the alignment of an optical system to align a substantially collimated light beam with an initial angular propagation direction along a Z axis, the method comprising:

obtaining an alignment compensation module which includes an afocal optical system configured to deviate the angular propagation direction of the light beam when rotated about a Y axis perpendicular to the initial angular propagation (Z axis) direction, the amount of deviation less than the amount of rotation of the afocal optical system; and

rotating the afocal optical system to adjust the path of the light beam through the optical system.

31. The method of claim 4 wherein the light beam is collimated.

32. The method of claim 4 wherein the light is substantially converging.

33. The method of claim 4 wherein the light is substantially diverging.

34. The method of claim 4 wherein the alignment compensation module includes a lens element.