US20030062345A1 - Apparatus and method for making a lens on the end of an optical waveguide fiber - Google Patents
Apparatus and method for making a lens on the end of an optical waveguide fiber Download PDFInfo
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- US20030062345A1 US20030062345A1 US09/966,916 US96691601A US2003062345A1 US 20030062345 A1 US20030062345 A1 US 20030062345A1 US 96691601 A US96691601 A US 96691601A US 2003062345 A1 US2003062345 A1 US 2003062345A1
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- Prior art keywords
- lens
- laser beam
- optical waveguide
- preform
- waveguide fiber
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/24—Coupling light guides
- G02B6/26—Optical coupling means
- G02B6/262—Optical details of coupling light into, or out of, or between fibre ends, e.g. special fibre end shapes or associated optical elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
- B23K26/04—Automatically aligning, aiming or focusing the laser beam, e.g. using the back-scattered light
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
- B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
- B23K26/064—Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms
- B23K26/066—Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms by using masks
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/24—Coupling light guides
- G02B6/255—Splicing of light guides, e.g. by fusion or bonding
- G02B6/2552—Splicing of light guides, e.g. by fusion or bonding reshaping or reforming of light guides for coupling using thermal heating, e.g. tapering, forming of a lens on light guide ends
Definitions
- GRIN gradient-index
- One aspect of the invention is an apparatus for making a lens on the end of an optical waveguide fiber.
- the apparatus includes a laser, wherein the laser emits a laser beam.
- the apparatus further includes a beam expander disposed to receive the laser beam, whereby the beam expander increases the diameter of the laser beam, thereby producing an expanded laser beam.
- the apparatus further includes a first aperture disposed within the expanded laser beam, wherein the first aperture blocks a portion of the expanded laser beam, and a second aperture disposed within the expanded laser beam, wherein the second aperture blocks a portion of the expanded laser beam.
- the apparatus further includes a first mirror disposed in the path of the expanded laser beam wherein the first mirror redirects the expanded laser beam.
- the apparatus further includes a focusing mirror disposed to receive the expanded laser beam, wherein the focusing mirror focuses the expanded laser beam thereby forming a heat zone.
- the apparatus further includes a first positioner disposed to selectively position at least a portion of a lens preform within the heat zone, and a second positioned disposed to selectively position at least a portion of an optical waveguide fiber within the heat zone.
- the present invention includes method for making a lens on the end of an optical waveguide fiber.
- the method includes the step of providing an optical waveguide fiber, the optical waveguide fiber having at least one end.
- the method further includes the steps of providing a lens preform and of coupling the lens preform to the at least one end, thereby forming a junction.
- the method further includes the steps of determining the volume of the lens overview or framework for understanding the nature and character of the invention as it is claimed.
- FIG. 2 is a cross section of a partially blocked laser beam in accordance with the present invention.
- FIG. 3 is a perspective view of one embodiment of a flat mirror used in the apparatus of FIG. 1;
- FIG. 5 is a perspective view of an alternative embodiment of the flat mirror shown in FIG. 3;
- FIG. 6 is a cross sectional view of a spherical mirror embodiment of the focusing mirror used in the apparatus of FIG. 1;
- FIG. 8 is a top plan view of the conical mirror of FIG. 7;
- FIG. 9 is a cross sectional view of a multi-conical mirror embodiment of the focusing mirror used in the apparatus of FIG. 1;
- FIG. 10 is a top plan view of the multi-conical mirror of FIG. 9;
- FIG. 10A is a graphical representation of the typical energy density as a function of length in the heat zone of the apparatus of FIG. 1 when the focusing mirror is a conical mirror;
- FIG. 10B is a graphical representation of the typical energy density as a function of length in the heat zone of the apparatus of FIG. 1 when the focusing mirror is a multi-conical mirror;
- FIG. 12 is a flowchart showing the fabrication steps of one embodiment of the present invention in block diagram form
- FIG. 13 is a flow chart showing the fabrication steps of one embodiment of the lens forming step of FIG. 12.
- FIG. 14 is a side elevation view of one embodiment of a fiber holder used in the apparatus of FIG. 1;
- FIG. 15 is an enlarged fragmentary view of a portion of the fiber holder shown in FIG. 14.
- FIG. 1 One embodiment of the present invention is an apparatus for making lenses on the end of an optical waveguide fiber is shown in FIG. 1 and is designated generally throughout by the reference numeral 10 .
- the apparatus 10 also includes a beam expander 18 disposed to expand the spot size of the laser beam 14 .
- the beam expander 18 emits an expanded laser beam 20 having a decreased energy density.
- the beam expander is a 4 ⁇ beam expanded and increases the spot size of the laser beam 16 from about 3 mm to about 12 mm.
- a first aperture 22 and a second aperture 24 are disposed in the path of the expanded laser beam 20 .
- the first and second apertures 22 , 24 are orthogonal to the expanded laser beam 20 and to one another.
- the first and second apertures 22 , 24 block a cruciform section of the expanded laser beam 20 .
- the center of the cruciform section of the expanded laser beam 20 that is blocked by the first and second apertures 22 , 24 is coincident with the center of the expanded laser beam 20 .
- FIG. 2 shows cross section of the expanded laser beam 20 at the plane 26 .
- the blocked cruciform section of the expanded laser beam 20 is useful in balancing the energy distribution of to the expanded laser beam 20 .
- the first and second apertures 22 , 24 may be, for example, stainless steel rods with a diameter of about 1.5 mm.
- the fiber holder 78 includes a tube 94 , as shown in FIG. 15, the end of the tube 94 is notched to receive the optical waveguide fiber 48 . Suction holds the optical waveguide fiber 48 against a reference surface 96 . The fiber holder 78 provides a way to securely hold the optical waveguide fiber 48 while at the same time inhibiting damage to the fiber while the position of the optical waveguide fiber 48 is being manipulated.
- a third actuator such as, for example a commercially available, stepper motor or servo having a 0.1 ⁇ m step may be used to drive the positioner stage in the Z direction, thereby allowing the optical waveguide fiber 48 to be brought into contact with a lens preform 30 .
- the displacement of the actuators and hence the position of the optical waveguide fiber 48 is controlled by a controller 76 that will be described in more detail below.
- a third actuator such as, for example a commercially available, stepper motor or servo having a 0.1 ⁇ m step may be used to drive the positioner stage in the Z direction
- the flat mirror 28 includes a groove 39 machined into the reflective surface.
- the groove 39 replaces the second aperture 26 while still producing an expanded laser beam with a centrally located cruciform section removed from the beam.
- the lens preform 30 may be, for example, a glass rod, such as, for example a silica glass rod having a diameter in the range from about 100 ⁇ m to about 350 ⁇ m.
- the lens preform 30 has a chemical composition chosen to allow the lens preform to be coupled to the optical waveguide fiber and have a desired refractive index so that lens formed on the end of the optical waveguide fiber will have desirable geometric and optical characteristics.
- the opening 46 is disposed to allow the lens preform 30 to be positioned coincident with the axis of symmetry of the focusing mirror 42 .
- the focusing mirror 42 may be, for example, a spherical mirror, a parabolic mirror, a conical mirror or a multi-conical mirror.
- FIG. 6 shows a cross sectional view of a spherical mirror embodiment of the focusing mirror 42 .
- FIG. 7 shows a cross sectional view of a conical mirror embodiment of the focusing mirror 42 , while FIG. 8 is a top plan view of the conical mirror embodiment of the focusing mirror 42 .
- An example of a multi-conical mirror is shown in FIG. 9 and FIG. 10. The choice of the type of mirror to use as the focusing mirror 42 depends upon the desired dimensions and energy distribution of the heat zone 44 .
- the size of the heat zone 44 is independent of the size of the reflected laser beam 34 .
- the energy density of the heat zone 44 is dependent upon the surface finish of the spherical mirror. For example if the energy density of the heat zone 44 is too great, it may be reduced by increasing the surface roughness of the spherical mirror. Conversely, if the if the energy density of the heat zone 44 is too low, it may be increased by decreasing the surface roughness of the spherical mirror.
- the size of the heat zone 44 from a spherical mirror is very small, the spherical mirror essentially focuses the reflected laser beam 34 to a single point.
- the size of the heat zone 44 depends upon the size of the reflected laser beam 34 .
- a conical mirror focuses a laser beam coincident with the axis of symmetry of the mirror into a heat zone 44 having a uniform energy density over a discrete length.
- the heat zone 44 has a length of about 3 mm.
- the fourth conical surface 54 has a base diameter 62 of about 0.080 inch and a cone angle ⁇ 4 of about 166 degrees. This particular arrangement of base diameters and cone angles, in conjunction with a laser beam 14 mm in diameter incident upon the multi-conical mirror 46 , results in a heat zone 44 of 1 mm in length and an axial energy distribution profile as shown in FIG. 10B.
- the multi-conical mirror 46 shown in FIG. 9 and FIG. 10 also includes a slot 64 .
- the slot 64 is about 0.040 inch wide and extends about 0.060 inch past the center of the multi-conical mirror 46 .
- the multi-conical mirror 46 is made of Tellurium Copper. As shown in FIG. 9 and FIG.
- the multi-conical mirror 46 includes a cylindrical potion 66 having a diameter D 1 of about 0.800 inch and a height of about 0.345 inch.
- the multi-conical mirror 46 also includes a mounting ring 68 having a diameter D 2 of about 1.000 inch and a thickness 70 of about 0.050 inch.
- the number of conical surfaces as well as the size and cone angles of the conical surfaces are all variables that may be changed individually or in combination to produce a heat zone 44 of desirable dimension and energy distribution for a particular application.
- the apparatus 10 also includes a positioning stage 38 .
- the positioning stage 38 is positioned below the focusing mirror 42 and feeds the optical waveguide fiber 48 through the opening 46 .
- the positioning stage 38 is capable of moving the lens preform 30 in reciprocal motion parallel to the axis of symmetry of the focusing mirror 42 as indicated by the arrow 74 .
- the positioning stage 38 is also capable of moving the optical waveguide fiber 48 in a plane transverse to the axis of symmetry of the focusing mirror 42 .
- the fiber feed mechanism 72 includes a positioning stage capable of translation in three orthogonal directions (X, Y, Z) and three actuators for driving the positioning stage.
- the positioner stage is located so that the X-Y plane of the positioner stage is transverse to the expanded laser beam 20 and preferably the expanded laser beam 20 is orthogonal to the X-Y plane of the positioner stage.
- the optical waveguide fiber 48 is mounted to the positioner, such as, for example a Newport 562 position stage, available from Newport Corporation of Irvine, Calif., USA.
- Two actuators such as, for example, Newport 850G closed loop Precision Actuators, available from Newport Corporation of Irvine, Calif., USA, drive the positioning stage in the X and Y directions.
- a third actuator such as, for example a commercially available, stepper motor or servo having a 0.1 ⁇ m step may be used to drive the positioner stage in the Z direction, thereby allowing the optical waveguide fiber 48 to be brought into contact with the lens preform 30 .
- the displacement of the actuators and hence the position of the optical waveguide fiber 48 is controlled by a controller 76 .
- the controller 76 is connected to the positioning stage 38 and the fiber feed mechanism 72 .
- the controller 76 aligns the lens preform 30 and the optical waveguide fiber 48 with one another.
- the digital computer 80 determines the physical location of the edges 82 , 84 , 86 , 88 , 90 , 92 with respect to a predetermined coordinate system.
- a mode filter algorithm has proven useful in reliably determining the location of the edges 83 , 84 , 86 , 88 , 90 , 92 within the reference coordinate system.
- the lens preform 30 is then fused to the optical waveguide fiber 48 and if necessary cut to length.
- the lens preform 30 is moved into the heat zone 44 and a lens is formed by melting the lens preform 30 and allowing the surface tension of the melted lens preform 30 to form the lens.
- a third digital camera (not shown) is used to provide another view of the lens which the digital computer 82 uses to characterize the lens.
- FIG. 2 Another embodiment of the method for making lenses of the present invention is shown in FIG. 2 and is designated generally throughout by the reference numeral 100 .
- the method 100 further includes the step 106 of coupling the lens preform to the optical waveguide fiber.
- the lens preform may be coupled to the optical waveguide fiber by fusing the lens preform to the optical waveguide fiber.
- the lens preform may be fused to the optical waveguide fiber by conventional electrode arc fusion splicing techniques.
- a laser such as, for example, a CO 2 laser may be used to splice the lens preform to the optical waveguide fiber.
- r is the cross-sectional radius of the lens preform.
- the method 100 further includes the step 110 of determining the length of the lens preform that corresponds to the estimated volume of the desired lens.
- the starting length, L start may be estimated according to equation 2.
- L start ( 4 3 ⁇ R c 3 ) r 2 + ( L fl - 2 ⁇ R c ) ( 2 )
- the method 100 further includes the step 112 of cutting the lens preform to length.
- the step 112 of cutting the lens preform to length produces and endface on the lens preform.
- the lens preform may be cut to length using a mechanical fiber cleaver or a laser.
- a laser is used in the step 106 to couple the lens preform to the optical waveguide fiber, either the lens preform moved or the laser beam is redirected so that the lens preform is sufficiently heated, at the distance equal to the starting length, L start , from the junction of the lens preform to the optical waveguide fiber, so that melting of the lens preform is initiated and surface tension pulls the glass apart, thus completing the cut.
- more than one laser beam may be used, such as, for example two laser beams of equal powerdirected to opposite sides of the lens preform.
- a precut lens preform may be used thus removing the need to cut the lens preform to length after coupling the lens preform to the optical waveguide fiber.
- the amount that distance between the heat source and the junction of the lens preform and the optical waveguide fiber must be decreased by to form the lens is the melt back distance, D MB .
- the melt back distance is estimated by equating the volume of the lens preform to be formed into the lens to the volume of the lens. For example, when the lens preform is cylindrical and the lens is spherical the the volume of the lens preform required to form the lens is denoted by V cylinder and volume of the formed lens is denoted by V sphere .V cylinder may be calculated using equation 3, where L MB if the length of the melt back.
- V sphere may be calculated according to equation 4.
- V sphere 4 3 ⁇ ⁇ ⁇ R c 3 ( 4 )
- L MB ( 4 3 ⁇ R c 3 ) r 2 ( 5 )
- the step 114 of forming the lens of the method 100 may further include the step 122 of measuring the geometric properties, specifically the radius of curvature, R c , and length of the lens element, L measured , as the lens as formed.
Abstract
The present invention relates to an apparatus and method for making a lens on the end of an optical waveguide fiber. The apparatus includes a laser, wherein the laser emits a laser beam. The apparatus further includes a beam expander disposed to receive the laser beam, whereby the beam expander increases the diameter of the laser beam, thereby producing an expanded laser beam. The apparatus further includes a first aperture disposed within the expanded laser beam, wherein the first aperture blocks a portion of the expanded laser beam, and a second aperture disposed within the expanded laser beam, wherein the second aperture blocks a portion of the expanded laser beam. The apparatus further includes a first mirror disposed in the path of the expanded laser beam wherein the first mirror redirects the expanded laser beam. The apparatus further includes a focusing mirror disposed to receive the expanded laser beam, wherein the focusing mirror focuses the expanded laser beam thereby forming a heat zone. The apparatus further includes a first positioner disposed to selectively position at least a portion of a lens preform within the heat zone, and a second positioned disposed to selectively position at least a portion of an optical waveguide fiber within the heat zone.
Description
- 1. Field of the Invention
- The present invention relates generally to lenses for optical waveguide fibers, and particularly to an apparatus and method of making lenses for optical waveguide fibers.
- 2. Technical Background
- Advances in optical communications have generated significant need for optical components that involve light being transmitted to or from an optical fiber through free-space to interact with or pass through one or more optical device. A wide variety of passive and active optical devices exist, some simple examples including thin-film filters or birefringent elements, and some of the more complex being large scale three-dimensional switch fabrics. Other uses for free-space optical components include injecting light from a laser diode into an optical fiber, transmitting light through free-space from one optical fiber to another (such as an amplifier fiber) or projecting light from an optical fiber to a detector.
- In optical components utilizing free-space transmission of light (sometimes called micro-optic components), the light beam is often either expanded and collimated into approximately parallel rays from the exposed end of an optical fiber, or conversely focused from an expanded beam into a narrower beam capable of being injected into the end of the optical fiber at a desired angle of incidence. While other functions may be performed on the light beam exiting or entering an optical fiber, collimating and focusing are the functions that are most commonly encountered in micro-optic components.
- In order to accomplish the collimating or focusing functions within the specifications required for optical communications, cylindrically-shaped gradient-index (GRIN) lenses employing graduated radial refractive index profiles have become the most prevalent conventional alternative. However, commercially-available GRIN lenses are expensive, difficult to manufacture, and present certain disadvantages in assembling, aligning, and tuning the optical components.
- Several other approaches to fabricating collimating or focusing lenses for optical components are known. Axial GRIN lenses, molded polymer and glass lenses having spherical and aspherical lens surfaces, composite or complex lens elements, optical fibers having integral lenses formed by processes such as thermal expansion or diffusion, and ball lenses are among the many alternatives.
- Thus there exits a need for a method of making lower cost precision lenses for optical components.
- One aspect of the invention is an apparatus for making a lens on the end of an optical waveguide fiber. The apparatus includes a laser, wherein the laser emits a laser beam. The apparatus further includes a beam expander disposed to receive the laser beam, whereby the beam expander increases the diameter of the laser beam, thereby producing an expanded laser beam. The apparatus further includes a first aperture disposed within the expanded laser beam, wherein the first aperture blocks a portion of the expanded laser beam, and a second aperture disposed within the expanded laser beam, wherein the second aperture blocks a portion of the expanded laser beam. The apparatus further includes a first mirror disposed in the path of the expanded laser beam wherein the first mirror redirects the expanded laser beam. The apparatus further includes a focusing mirror disposed to receive the expanded laser beam, wherein the focusing mirror focuses the expanded laser beam thereby forming a heat zone. The apparatus further includes a first positioner disposed to selectively position at least a portion of a lens preform within the heat zone, and a second positioned disposed to selectively position at least a portion of an optical waveguide fiber within the heat zone.
- In another aspect, the present invention includes method for making a lens on the end of an optical waveguide fiber. The method includes the step of providing an optical waveguide fiber, the optical waveguide fiber having at least one end. The method further includes the steps of providing a lens preform and of coupling the lens preform to the at least one end, thereby forming a junction. The method further includes the steps of determining the volume of the lens overview or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention, and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments of the invention, and together with the description serve to explain the principles and operations of the invention.
- FIG. 1 is a schematic diagram of an apparatus embodiment of the present invention;
- FIG. 2 is a cross section of a partially blocked laser beam in accordance with the present invention.
- FIG. 3 is a perspective view of one embodiment of a flat mirror used in the apparatus of FIG. 1;
- FIG. 4 is a cross sectional view of the flat mirror if FIG. 3;
- FIG. 5 is a perspective view of an alternative embodiment of the flat mirror shown in FIG. 3;
- FIG. 6 is a cross sectional view of a spherical mirror embodiment of the focusing mirror used in the apparatus of FIG. 1;
- FIG. 7 is a cross sectional view of a conical mirror embodiment of the focusing mirror used in the apparatus of FIG. 1;
- FIG. 8 is a top plan view of the conical mirror of FIG. 7;
- FIG. 9 is a cross sectional view of a multi-conical mirror embodiment of the focusing mirror used in the apparatus of FIG. 1;
- FIG. 10 is a top plan view of the multi-conical mirror of FIG. 9;
- FIG. 10A is a graphical representation of the typical energy density as a function of length in the heat zone of the apparatus of FIG. 1 when the focusing mirror is a conical mirror;
- FIG. 10B is a graphical representation of the typical energy density as a function of length in the heat zone of the apparatus of FIG. 1 when the focusing mirror is a multi-conical mirror;
- FIG. 11 is a side elevation view of the lens preform and optical waveguide fiber acted upon by the apparatus of FIG. 1 prior to alignment and forming the lens;
- FIG. 12 is a flowchart showing the fabrication steps of one embodiment of the present invention in block diagram form;
- FIG. 13 is a flow chart showing the fabrication steps of one embodiment of the lens forming step of FIG. 12; and
- FIG. 14 is a side elevation view of one embodiment of a fiber holder used in the apparatus of FIG. 1; and
- FIG. 15 is an enlarged fragmentary view of a portion of the fiber holder shown in FIG. 14.
- Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.
- One embodiment of the present invention is an apparatus for making lenses on the end of an optical waveguide fiber is shown in FIG. 1 and is designated generally throughout by the reference numeral10.
- The present invention for an apparatus10 for making lenses on the end of an optical waveguide fiber includes a
laser 12, such as, for example a 10W CO2 laser having a wavelength of 10.6 μm. The laser is coupled to acontroller 14 that controls the duration and power of thelaser beam 16. In one embodiment thelaser 12 emits alaser beam 16 having a spot size of 3 mm. It will be apparent to those skilled in the pertinent art, however, that the spot size of thelaser beam 16 and output power of thelaser 12 are design choices that may very with the optics used in the apparatus 10 or with the desired lens geometry. - The apparatus10 also includes a
beam expander 18 disposed to expand the spot size of thelaser beam 14. The beam expander 18 emits an expandedlaser beam 20 having a decreased energy density. In one embodiment of the present invention, the beam expander is a 4× beam expanded and increases the spot size of thelaser beam 16 from about 3 mm to about 12 mm. - A
first aperture 22 and asecond aperture 24 are disposed in the path of the expandedlaser beam 20. The first andsecond apertures laser beam 20 and to one another. The first andsecond apertures laser beam 20. Preferably, the center of the cruciform section of the expandedlaser beam 20 that is blocked by the first andsecond apertures laser beam 20. FIG. 2 shows cross section of the expandedlaser beam 20 at the plane 26. The blocked cruciform section of the expandedlaser beam 20 is useful in balancing the energy distribution of to the expandedlaser beam 20. Returning to FIG. 1, the first andsecond apertures - The apparatus10 also includes a
flat mirror 28. Theflat mirror 28 is inclined at an angle of about 45 degrees with respect to theaxis 30 of the expandedlaser beam 20. Theflat mirror 28 may be, for example, a copper mirror. FIG. 3 and FIG. 4 show one possible embodiment of theflat mirror 28. Theflat mirror 28 is adapted to allow anoptical waveguide fiber 48, such as for example a SMF-28™ optical waveguide fiber, available from Corning Incorporated of Corning, N.Y., USA, to pass through theflat mirror 28. Preferably, theflat mirror 28 is configured with anopening 32, such as, for example a hole or slot, that allows theoptical waveguide fiber 48 to positioned in the center of the reflected laser beam 34. Preferably, the opening foroptical waveguide fiber 48 in theflat mirror 28 is located in the mirror so as to fall within the blocked portion of the expandedlaser beam 20. - The apparatus10 also includes a
fiber feed mechanism 72. Thefiber feed mechanism 72 is positioned above theflat mirror 28 and feeds theoptical waveguide fiber 48 through theopening 32. Thefiber feed mechanism 72 is capable of moving theoptical waveguide fiber 48 in reciprocal motion parallel to the axis of the reflected laser beam 34 as indicated by the arrow 74. Thefiber feed mechanism 72 is also capable of moving theoptical waveguide fiber 48 in a plane transverse to the axis of the reflected laser beam 34. Thefiber feed mechanism 72 may include afiber holder 78. In one embodiment, as shown in FIG. 14 and FIG. 15, thefiber holder 78 is vacuum device that uses suction to hold the end of theoptical waveguide fiber 48. Thefiber holder 78 includes atube 94, as shown in FIG. 15, the end of thetube 94 is notched to receive theoptical waveguide fiber 48. Suction holds theoptical waveguide fiber 48 against areference surface 96. Thefiber holder 78 provides a way to securely hold theoptical waveguide fiber 48 while at the same time inhibiting damage to the fiber while the position of theoptical waveguide fiber 48 is being manipulated. - In one embodiment the
fiber feed mechanism 72 includes a positioning stage capable of translation in three orthogonal directions (X, Y, Z) and three actuators for driving the positioning stage. The positioner stage is located so that the X-Y plane of the positioner stage is transverse to the reflected laser beam 34 and preferably the reflected laser beam 34 is orthogonal to the X-Y plane of the positioner stage. Theoptical waveguide fiber 48 is mounted to the positioner, such as, for example a Newport 562 position stage, available from Newport Corporation of Irvine, Calif., USA. Two actuators, such as, for example, Newport 850G closed loop Precision Actuators, available from Newport Corporation of Irvine, Calif., USA, drive the positioning stage in the X and Y directions. A third actuator, such as, for example a commercially available, stepper motor or servo having a 0.1 μm step may be used to drive the positioner stage in the Z direction, thereby allowing theoptical waveguide fiber 48 to be brought into contact with alens preform 30. The displacement of the actuators and hence the position of theoptical waveguide fiber 48 is controlled by acontroller 76 that will be described in more detail below. - Returning to FIG. 1, the
lens preform 30 is secured by aclamp 36 to apositioning stage 38 capable of translation along three (3) orthogonal axes (X, Y, Z), such as, for example a Newport 562 position stage, available from Newport Corporation of Irvine, Calif., USA. Thepositioning stage 38 is located so that the X-Y plane of the positioner stage is transverse to the expandedlaser beam 20 and preferably the reflected laser beam 34 is orthogonal to the X-Y plane of the positioner stage. Two actuators, such as, for example, Newport 850G closed loop Precision Actuators, available from Newport Corporation of Irvine, Calif., USA, drive the positioning stage in the X and Y directions. This allows thelens preform 30 to be positioned within the reflected laser beam 34. A third actuator, such as, for example a commercially available, stepper motor or servo having a 0.1 μm step may be used to drive the positioner stage in the Z direction - In an alternative embodiment, as shown in FIG. 5, the
flat mirror 28 includes agroove 39 machined into the reflective surface. Thegroove 39 replaces the second aperture 26 while still producing an expanded laser beam with a centrally located cruciform section removed from the beam. - Returning to FIG. 1, the apparatus10 also includes a focusing
mirror 42. The focusingmirror 42 is an axisymmetric focusing mirror that focuses the expanded laser beam to aheat zone 44. The focusingmirror 42 includes anopening 46 sized to allow alens preform 30, such as for example a glass rod to pass through the focusingmirror 42. Thelens preform 30 is a glass body, such as, for example a cylinder of glass. The shape of the preform depends upon the final geometry of the lens to be formed and may be any geometric cross-section, such as, for example circular, triangular, rectangular, hexagonal, octagonal, annular, C-shaped, V-shaped, or H-shaped. Thelens preform 30 may be, for example, a glass rod, such as, for example a silica glass rod having a diameter in the range from about 100 μm to about 350 μm. Thelens preform 30 has a chemical composition chosen to allow the lens preform to be coupled to the optical waveguide fiber and have a desired refractive index so that lens formed on the end of the optical waveguide fiber will have desirable geometric and optical characteristics. Preferably, theopening 46 is disposed to allow thelens preform 30 to be positioned coincident with the axis of symmetry of the focusingmirror 42. - The focusing
mirror 42 may be, for example, a spherical mirror, a parabolic mirror, a conical mirror or a multi-conical mirror. FIG. 6 shows a cross sectional view of a spherical mirror embodiment of the focusingmirror 42. FIG. 7 shows a cross sectional view of a conical mirror embodiment of the focusingmirror 42, while FIG. 8 is a top plan view of the conical mirror embodiment of the focusingmirror 42. An example of a multi-conical mirror is shown in FIG. 9 and FIG. 10. The choice of the type of mirror to use as the focusingmirror 42 depends upon the desired dimensions and energy distribution of theheat zone 44. For a spherical mirror, the size of theheat zone 44 is independent of the size of the reflected laser beam 34. When the focusingmirror 42 is a spherical mirror, the energy density of theheat zone 44 is dependent upon the surface finish of the spherical mirror. For example if the energy density of theheat zone 44 is too great, it may be reduced by increasing the surface roughness of the spherical mirror. Conversely, if the if the energy density of theheat zone 44 is too low, it may be increased by decreasing the surface roughness of the spherical mirror. The size of theheat zone 44 from a spherical mirror is very small, the spherical mirror essentially focuses the reflected laser beam 34 to a single point. - For conical and multi-conical mirrors, such as, for example those shown in FIGS. 7, 8,9, and 10, the size of the
heat zone 44 depends upon the size of the reflected laser beam 34. As shown in FIG. 10A, a conical mirror focuses a laser beam coincident with the axis of symmetry of the mirror into aheat zone 44 having a uniform energy density over a discrete length. For example, for a laser beam with a diameter of 12 mm and a conical mirror with a cone angle of about 143 degrees, theheat zone 44 has a length of about 3 mm. The type of focusingmirror 42 used in important in being able to tailor the energy density throughout theheat zone 44. - FIG. 9 is a cross-sectional view of a
multi-conical mirror 46 that may be used as the focusingmirror 42. Themulti-conical mirror 46 shown in FIG. 9 and FIG. 10 includes 4conical surfaces base diameter 56 of about 0.348 inch and a cone angle α1 of about 120 degrees. The secondconical surface 50 has abase diameter 58 of about 0.252 inch and a cone angle α2 of about 136 degrees. The thirdconical surface 52 has abase diameter 60 of about 0.142 inch and a cone angle α3 of about 156 degrees. The fourthconical surface 54 has abase diameter 62 of about 0.080 inch and a cone angle α4 of about 166 degrees. This particular arrangement of base diameters and cone angles, in conjunction with alaser beam 14 mm in diameter incident upon themulti-conical mirror 46, results in aheat zone 44 of 1 mm in length and an axial energy distribution profile as shown in FIG. 10B. Themulti-conical mirror 46 shown in FIG. 9 and FIG. 10 also includes aslot 64. Theslot 64 is about 0.040 inch wide and extends about 0.060 inch past the center of themulti-conical mirror 46. Themulti-conical mirror 46 is made of Tellurium Copper. As shown in FIG. 9 and FIG. 10 themulti-conical mirror 46 includes acylindrical potion 66 having a diameter D1 of about 0.800 inch and a height of about 0.345 inch. Themulti-conical mirror 46 also includes a mountingring 68 having a diameter D2 of about 1.000 inch and athickness 70 of about 0.050 inch. - As will be appreciated by those of ordinary skill in the optical arts, the number of conical surfaces as well as the size and cone angles of the conical surfaces are all variables that may be changed individually or in combination to produce a
heat zone 44 of desirable dimension and energy distribution for a particular application. - The size and shape of the first and
second apertures 24, 26 and the optical characteristics of the focusingmirror 42 control the shape of the lens. In some optical applications for example it may be desirable to have a lens that has different radii of curvature in orthogonal directions, such as, for example when optically coupling an optical waveguide fiber to the elliptical beam from a laser diode. - Returning to FIG. 1, the apparatus10 also includes a
positioning stage 38. Thepositioning stage 38 is positioned below the focusingmirror 42 and feeds theoptical waveguide fiber 48 through theopening 46. Thepositioning stage 38 is capable of moving thelens preform 30 in reciprocal motion parallel to the axis of symmetry of the focusingmirror 42 as indicated by the arrow 74. Thepositioning stage 38 is also capable of moving theoptical waveguide fiber 48 in a plane transverse to the axis of symmetry of the focusingmirror 42. - In one embodiment the
fiber feed mechanism 72 includes a positioning stage capable of translation in three orthogonal directions (X, Y, Z) and three actuators for driving the positioning stage. The positioner stage is located so that the X-Y plane of the positioner stage is transverse to the expandedlaser beam 20 and preferably the expandedlaser beam 20 is orthogonal to the X-Y plane of the positioner stage. Theoptical waveguide fiber 48 is mounted to the positioner, such as, for example a Newport 562 position stage, available from Newport Corporation of Irvine, Calif., USA. Two actuators, such as, for example, Newport 850G closed loop Precision Actuators, available from Newport Corporation of Irvine, Calif., USA, drive the positioning stage in the X and Y directions. A third actuator, such as, for example a commercially available, stepper motor or servo having a 0.1 μm step may be used to drive the positioner stage in the Z direction, thereby allowing theoptical waveguide fiber 48 to be brought into contact with thelens preform 30. The displacement of the actuators and hence the position of theoptical waveguide fiber 48 is controlled by acontroller 76. Thecontroller 76 is connected to thepositioning stage 38 and thefiber feed mechanism 72. Thecontroller 76 aligns thelens preform 30 and theoptical waveguide fiber 48 with one another. - The
controller 76 includes afirst camera 78 and asecond camera 80. The first andsecond cameras second cameras heat zone 44 is substantially centered within the respective field of views of first andsecond cameras second cameras second cameras laser beam 20. - The first and
second cameras digital computer 82. An example of a digital image transmitted by either the first orsecond camera digital computer 82 uses a edge detection algorithm, such as for example a SORBEL algorithm to identify theedges lens preform 30 and theedges optical waveguide fiber 72. - After the
edges digital computer 80 determines the physical location of theedges edges edges digital computer 80 directs the positingstage 38 andfiber feed mechanism 72 to move thelens preform 30 and theoptical waveguide fiber 48 into alignment with one another. Thelens preform 30 is then fused to theoptical waveguide fiber 48 and if necessary cut to length. Thelens preform 30 is moved into theheat zone 44 and a lens is formed by melting thelens preform 30 and allowing the surface tension of the meltedlens preform 30 to form the lens. - After the lens is formed, the
digital computer 82 uses images from the first andsecond cameras - In an alternative embodiment, a third digital camera (not shown) is used to provide another view of the lens which the
digital computer 82 uses to characterize the lens. - Another embodiment of the method for making lenses of the present invention is shown in FIG. 2 and is designated generally throughout by the
reference numeral 100. - The present invention for a
method 100 of making a lens on the end of an optical waveguide fiber includes thestep 102 of providing an optical waveguide fiber, such as, for example SMF-28™ single mode optical waveguide fiber, available from Corning Incorporated of Corning, N.Y. Themethod 100 further includes thestep 104 of providing a lens preform. The lens preform is a glass body, such as, for example a cylinder of glass. The shape of the preform depends upon the final geometry of the lens to be formed and may be any geometric cross-section, such as, for example circular, triangular, rectangular, hexagonal, octagonal, annular, C-shaped, V-shaped, or H-shaped. - The lens preform has a chemical composition chosen to allow the lens preform to be coupled to the optical waveguide fiber and have a desired refractive index so that lens formed on the end of the optical waveguide fiber will have desirable geometric and optical characteristics. The lens preform may, for example, be a silica glass fiber having a diameter from about 100 μm to about 300 μm when the optical waveguide fiber is SMF-28™ single mode optical waveguide fiber.
- The
method 100 further includes thestep 106 of coupling the lens preform to the optical waveguide fiber. The lens preform may be coupled to the optical waveguide fiber by fusing the lens preform to the optical waveguide fiber. The lens preform may be fused to the optical waveguide fiber by conventional electrode arc fusion splicing techniques. Alternatively a laser, such as, for example, a CO2 laser may be used to splice the lens preform to the optical waveguide fiber. - The
method 100 further includes thestep 108 of determining the volume of the lens to be formed. For example, for a lens having a desired overall length Lfl and a front surface radius of curvature Rc , when the lens preform is circular in cross-section the total volume of the lens, Vlens, is calculated according to equation 1. It should be noted that equation 1 only provides an estimation of the volume of the desired lens. - where, r is the cross-sectional radius of the lens preform.
-
- As will be appreciated by those skilled in the pertinent art, for the starting length may be calculated by employing the appropriate geometric formulas.
- The
method 100 further includes thestep 112 of cutting the lens preform to length. Thestep 112 of cutting the lens preform to length produces and endface on the lens preform. The lens preform may be cut to length using a mechanical fiber cleaver or a laser. When a laser is used in thestep 106 to couple the lens preform to the optical waveguide fiber, either the lens preform moved or the laser beam is redirected so that the lens preform is sufficiently heated, at the distance equal to the starting length, Lstart, from the junction of the lens preform to the optical waveguide fiber, so that melting of the lens preform is initiated and surface tension pulls the glass apart, thus completing the cut. As will be appreciated by those skilled in the pertinent art, more than one laser beam may be used, such as, for example two laser beams of equal powerdirected to opposite sides of the lens preform. Alternatively, a precut lens preform may be used thus removing the need to cut the lens preform to length after coupling the lens preform to the optical waveguide fiber. - The
method 100 further includes thestep 114 of forming the lens. The step of forming the lens may include thestep 116 of measuring the distance from the junction of the lens preform and the optical waveguide fiber to the end of the lens preform. Based upon this measured distance, the necessary relative movement between the heat source and junction, and the power setting of the heat source that are required to form a desired lens shape may be estimated. If a precut lens preform is used thestep 116 of measuring the distance from the junction of the lens preform and the optical waveguide fiber to the end of the lens preform may be omitted. - The
step 114 of forming the lens of themethod 100 may further include thestep 118 providing a heat source, such as, for example a laser. Thestep 114 includes the step of applying heat to the endface of the lens preform, thereby melting the endface of the lens preform. The surface tension of the glass forms a curved front surface. Thestep 118 of applying heat to the endface of the lens preform may also include thestep 120 of decreasing the distance between the heat source and the junction of the lens preform and the optical waveguide fiber. The distance between the heat source and the junction of the lens preform and the optical waveguide fiber may be decreased by moving the junction relative while the heat source remains stationary or by moving the heat source while the junction remains stationary. The amount that distance between the heat source and the junction of the lens preform and the optical waveguide fiber must be decreased by to form the lens is the melt back distance, DMB. The melt back distance is estimated by equating the volume of the lens preform to be formed into the lens to the volume of the lens. For example, when the lens preform is cylindrical and the lens is spherical the the volume of the lens preform required to form the lens is denoted by Vcylinder and volume of the formed lens is denoted by Vsphere.Vcylinder may be calculated using equation 3, where LMB if the length of the melt back. - V cylinder =π·r 2 ·L MB (3)
-
-
- The melt back distance DMB is calculated by substituting this value of LMB into
equation 6. - D MB =L MB−2·R c (6)
- The
step 114 of forming the lens of themethod 100 may further include thestep 122 of measuring the geometric properties, specifically the radius of curvature, Rc, and length of the lens element, Lmeasured, as the lens as formed. - The
step 114 of forming the lens of themethod 100 may further include the step 124 of using the measured values of the lens length, Lmeasured, and radius of curvature, Rc, as input data for a control algorithm that controls the power of the heat source P and the relative displacement between the heat source and the junction of the lens preform and the optical waveguide fiber for the formation of the next lens. - It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
Claims (22)
1. An apparatus for making a lens on the end of an optical waveguide fiber comprising:
a laser, wherein said laser emits a laser beam;
a beam expander disposed to receive the laser beam, whereby said beam expander increases the diameter of the laser beam, thereby producing an expanded laser beam;
a first aperture disposed within said expanded laser beam, wherein said first aperture blocks a portion of said expanded laser beam;
a second aperture disposed within said expanded laser beam, wherein said second aperture blocks a portion of said expanded laser beam;
a first mirror disposed in the path of said expanded laser beam wherein said first mirror redirects said expanded laser beam;
a focusing mirror disposed to receive said expanded laser beam, wherein said focusing mirror focuses said expanded laser beam thereby forming a heat zone;
a first positioner disposed to selectively position at least a portion of a lens preform within said heat zone; and
a second positioned disposed to selectively position at least a portion of an optical waveguide fiber within said heat zone.
2. The apparatus of claim 1 further including a controller;
wherein said controller is coupled to said first positioned, whereby said controller activates said first positioner to selectively position said at least a portion of said lens preform within said heat zone;
wherein said controller is coupled to said second positioner, whereby said controller activates said second positioner to selectively position said at least a portion of said optical waveguide fiber within said heat zone;
wherein said controller is coupled to said laser, whereby said controller adjust the output power of said laser.
3. The apparatus of claim 2 wherein said controller includes:
a first camera, wherein the field of view of said first camera includes said heat zone;
a second camera disposed perpendicular to said first camera, wherein the field of view of said second camera includes said heat zone;
wherein said first camera and said second camera are disposed radially with respect to said expanded laser beam; and
wherein said first and second cameras are located in a plane perpendicular to said expanded laser beam.
4. The apparatus of claim 3 wherein said controller further includes:
a digital computer coupled to said first camera and said second camera, wherein said digital computer receives a first image from said first camera and a second image from said second camera and wherein said digital computer uses said first and second images to control said first and second positioners thereby locating said lens preform and said optical waveguide fiber in a predetermined relationship to one another.
5. A method of making a lens on the end of an optical fiber comprising the steps of:
providing an optical waveguide fiber, the optical waveguide fiber having at least one end;
providing a lens preform;
coupling the lens preform to the at least one end, thereby forming a junction;
determining the volume of the lens to be formed;
determining the length of the lens preform that corresponds to the determined volume;
removing the portion of the lens preform that is in excess of the volume of the lens to be formed; and
forming the lens.
6. The method of claim 5 wherein the diameter of the lens preform is greater than the diameter of the optical waveguide fiber.
9. The method of claim 5 , wherein the step of providing a cylindrical glass fiber includes the step of providing a cylindrical silica glass fiber.
10. The method of claim 5 wherein the steps of:
determining the volume of the lens to be formed;
determining the length of the lens preform that corresponds to the determined volume; and
removing the portion of the lens preform that is in excess of the volume of the lens to be formed, thereby producing an endface on the lens preform;
are preformed prior to the step of coupling the lenspreform to the at least one end.
11. The method of claim 5 wherein the step of forming the lens includes the step of forming an aspherical lens.
12. The method of claim 5 wherein the step of forming the lens includes the step of forming an spherical lens.
13. The method of claim 12 wherein the step of forming the spherical lens includes the steps of:
providing a heat source;
heating the endface of the lens preform; and
moving the junction a distance toward the heat source.
15. The method of claim 5 wherein the step of forming the lens includes the step of forming an ball lens.
16. The method of claim 5 further including the step of characterizing the lens.
17. The method of claim 16 wherein the step of characterizing the lens includes the step of measuring the geometry of the lens.
18. The method of claim 17 further includes the step of comparing the measured geometry of the lens to a desired lens geometry.
19. The method of claim 18 further including the step of adjusting the output of the heat source.
20. The method of claim 19 , wherein the heat source is a laser and the step of adjusting the output of the heat source includes adjusting the output power of the laser.
21. The method of claim 18 further including the step of adjusting the melt back displacement.
22. The method of claim 18 further including the step of adjusting the taper cut displacement.
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/966,916 US6552298B1 (en) | 2001-09-28 | 2001-09-28 | Apparatus and method for making a lens on the end of an optical waveguide fiber |
PCT/US2002/029957 WO2003029853A2 (en) | 2001-09-28 | 2002-09-20 | Apparatus and method for making a lens on the end of an optical waveguide fiber |
AU2002334621A AU2002334621A1 (en) | 2001-09-28 | 2002-09-20 | Apparatus and method for making a lens on the end of an optical waveguide fiber |
TW091122784A TWI252340B (en) | 2001-09-28 | 2002-09-28 | Apparatus and method for making a lens on the end of an optical waveguide fiber |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US09/966,916 US6552298B1 (en) | 2001-09-28 | 2001-09-28 | Apparatus and method for making a lens on the end of an optical waveguide fiber |
Publications (2)
Publication Number | Publication Date |
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US20030062345A1 true US20030062345A1 (en) | 2003-04-03 |
US6552298B1 US6552298B1 (en) | 2003-04-22 |
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US09/966,916 Expired - Fee Related US6552298B1 (en) | 2001-09-28 | 2001-09-28 | Apparatus and method for making a lens on the end of an optical waveguide fiber |
Country Status (4)
Country | Link |
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US (1) | US6552298B1 (en) |
AU (1) | AU2002334621A1 (en) |
TW (1) | TWI252340B (en) |
WO (1) | WO2003029853A2 (en) |
Cited By (2)
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US20080044059A1 (en) * | 2006-06-26 | 2008-02-21 | Orbotech Ltd. | Alignment of printed circuit board targets |
US20170266757A1 (en) * | 2013-12-17 | 2017-09-21 | Corning Incorporated | Transparent material cutting with ultrafast laser and beam optics |
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US7082250B2 (en) * | 2004-04-15 | 2006-07-25 | Furukawn Electric North America, Inc. | Laser cleaving method and apparatus for optical fiber cables |
US8218928B2 (en) | 2009-04-23 | 2012-07-10 | Ofs Fitel, Llc | Spatial filtering of higher order modes in multimode fibers |
US8430576B2 (en) * | 2011-03-15 | 2013-04-30 | Intel Corporation | Fiber termination in light peak lenses |
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2001
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-
2002
- 2002-09-20 AU AU2002334621A patent/AU2002334621A1/en not_active Abandoned
- 2002-09-20 WO PCT/US2002/029957 patent/WO2003029853A2/en not_active Application Discontinuation
- 2002-09-28 TW TW091122784A patent/TWI252340B/en not_active IP Right Cessation
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US20080044059A1 (en) * | 2006-06-26 | 2008-02-21 | Orbotech Ltd. | Alignment of printed circuit board targets |
US7945087B2 (en) | 2006-06-26 | 2011-05-17 | Orbotech Ltd. | Alignment of printed circuit board targets |
US20170266757A1 (en) * | 2013-12-17 | 2017-09-21 | Corning Incorporated | Transparent material cutting with ultrafast laser and beam optics |
Also Published As
Publication number | Publication date |
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WO2003029853A2 (en) | 2003-04-10 |
AU2002334621A1 (en) | 2003-04-14 |
US6552298B1 (en) | 2003-04-22 |
WO2003029853A3 (en) | 2003-07-31 |
TWI252340B (en) | 2006-04-01 |
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