Optical system active alignment process including alignment structure attach, position search, and deformation

• US 6,559,464 B1
• Filed: 08/25/2000
• Issued: 05/06/2003
• Est. Priority Date: 11/15/1999
• Status: Expired due to Term

• Current Assignee: Axsun Technologies Incorporated
• Original Assignee: Axsun Technologies Incorporated
• Inventors: Flanders, Dale C., Whitney, Peter S.
• Primary Examiner(s): LE, QUE TAN
• Application Number:
  US09/648,148
• Time in Patent Office: 984 Days
• Field of Search: 250/548, 250/559.3, 250/559.33, 250/216, 385/88, 385/90, 385/73
• US Class Current: 250/548
• CPC Class Codes: G02B 27/62 Optical apparatus specially adapted for adjusting optical elements during the assembly of optical systems
• 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 6/327 with angled interfaces to reduce reflections
• CPC Class Codes: G02B 6/3586 Control or adjustment details, e.g. calibrating testing optical equipment G01M11/00
• CPC Class Codes: G02B 6/3636 the mechanical coupling means being grooves G02B6/3652 takes precedence
• CPC Class Codes: G02B 6/3644 the coupling means being through-holes or wall apertures
• CPC Class Codes: G02B 6/3656 the additional structures being micropositioning, with microactuating elements for fine adjustment, or restricting movement, into two dimensions, e.g. cantilevers, beams, tongues or bridges with associated MEMs
• CPC Class Codes: G02B 6/3692 with surface micromachining involving etching, e.g. wet or dry etching steps surface micromachining involving subtractive techniques B81C1/00055
• CPC Class Codes: G02B 6/4201 Packages, e.g. shape, construction, internal or external details
• 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 6/4237 Welding
• CPC Class Codes: G02B 6/4238 Soldering
• CPC Class Codes: G02B 6/4243 Mounting of the optical light guide into a groove mounting optical light guides into a groove in general G02B6/3636
• CPC Class Codes: G02B 6/4249 comprising arrays of active devices and fibres
• CPC Class Codes: G02B 6/4256 Details of housings
• CPC Class Codes: G02B 7/003 Alignment of optical elements G02B7/001, G02B7/002 take precedence; for mirrors G02B7/1822

Abstract

Mounting and alignment structures for optical components allow optical components to be connected to an optical bench and then subsequently aligned, i.e., either passively or actively, in a manufacturing or subsequent calibration or recalibration, alignment or realignment processes. The structures comprise quasi-extrusion portions. This portion is “quasi-extrusion” in the sense that it has a substantially constant cross section in a z-axis direction as would be yielded in an extrusion manufacturing process. The structures further comprise at least one base, having a laterally-extending base surface, and an optical component interface. At least one armature connects the optical component interface with the base. In the preferred embodiment, the base surface is securable to an optical bench.

Claims

1. An optical system active alignment process comprising:

attaching an alignment structure to an optical bench;

measuring an optical signal after interaction with an optical component held on the alignment structure;

an alignment system engaging and deforming the alignment structure in response to the optical signal to find a desired position for the optical component; and

after the desired position is found, the alignment system engaging and plastically deforming the alignment structure so that the optical component of the alignment structure will be at the desired position when the alignment system disengages from the alignment structure.

2. A process as claimed in claim 1, wherein the step of engaging and deforming the alignment structure comprises applying force to the structure to elastically and/or plastically deform the alignment structure while detecting a magnitude of the optical signal.

3. A process as claimed in claim 1, wherein the step of engaging and deforming the alignment structure comprises engaging the alignment structure at a handle thereof.

4. A process as claimed in claim 1, wherein the step of engaging and plastically deforming the alignment structure comprises deforming the alignment structure beyond the desired position for the optical component to account of elastic movement of the alignment structure after disengagement from the structure by the alignment system.

5. A process as claimed in claim 1, wherein the step of engaging and plastically deforming the alignment structure to locate the optical component at the desired position comprises moving the optical component in a plane that is orthogonal to a propagation direction of the optical signal at the optical component while maintaining a position of the optical component along an axis that is parallel to the propagation direction of the optical signal.