US 6,625,351 B2 · Ink-jet printing of collimating microlenses onto optical fibers

Abstract

Collimating microlenses are “printed” from optical polymeric materials on the ends of optical fibers using ink-jet technology. In one embodiment the optical fibers are inserted into a collet, a stand-off distance from the open upper end of the collet. The open upper end is filled with optical fluid and a microlens is formed thereon to collimate light exiting the fiber through the microlens. In another embodiment optical fibers from a “ribbon” are separated and installed into a ferrule having multiple openings therethrough. In the same manner as in the collet embodiment, the ferrule openings serve as a mold for the lens formation with the end of the fiber being located at the focal distance of the lenslet formed in an on the ferrule. A non-wetting coating can serve to control spreading of the fluid optical material and allow lens radius control as well. The microlenses are hardened after formation.

Claims23

Dependent claims

A method of fabricating collimating microlenses for the ends of optical fibers by means of ink-jet printing comprising:

selecting a desired lens geometry;
providing a hollow collet having an opening therethrough sized to accept an optical fiber, the collet having open lower and upper ends;
inserting the tip of an optical fiber into the open lower end of the collet;
fixing the optical fiber in the collet with its tip spaced from the upper end of the collet by a standoff distance which will place the focal length of the microlens to be formed at the tip of the optical fiber;
depositing droplets of fluid microlens material into the open upper end of the collet by means of an ink-jet printhead until the opening within the collet is filled and a microlens of the desired geometry is formed thereon, and
curing the microlens material.

3 more elements

A method of fabricating collimating microlenses for the ends of optical fibers within a fiber array by means of inkjet printing, comprising:

selecting a collimating microlens having a diameter, radius of curvature and focal length;
providing a ferrule having a plurality of openings therethrough, the openings having a lower end and an upper end and being sized to accept separated optical fibers from a fiber array;
inserting the tips of separate optical fibers in the lower ends of the plurality of openings and fixing the fibers in the ferrule with their tips at the focal length of the selected collimating microlens;
forming pedestals of microlens material extending from the tips of the optical fibers to the top of the ferrule by depositing droplets of fluid microlens material into the upper ends of the plurality of openings of the ferrule using an ink-jet printhead;
building collimating microlens above each of the upper ends of the plurality of openings in the ferrule using said printhead;
and
curing the microlens material in the ferrule.

4 more elements

Dependencies are inferred from the claim text.

Ink-jet printing of collimating microlenses onto optical fibers

Life of this patent

Ink-jet printing of collimating microlenses onto optical fibers

Life of this patent

Abstract

Claims23