Microlenses for optical assemblies and related methods
AssigneeCorning Incorporated
InventorsRichard Robert Grzybowski, Stephan Lvovich Logunov, Alexander Mikhailovich Streltsov
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Abstract
Microlenses are formed on a substrate having a first absorption within an operational wavelength range, and a second absorption outside the operational wavelength range, wherein the second absorption is greater than the first absorption. One or more waveguides are coupled with a processing light beam having a wavelength outside the operational wavelength range, and the processing light beam is directed through the waveguides to the substrate to locally heat and expand the substrate so as to form microlenses on the substrate surface. The processing light beam is terminated to stop heating of the substrate and fix the microlenses.
Claims25
A method of making an optical assembly, the method comprising:
- providing a substrate having a surface, the substrate having a first absorption within an operational wavelength range, and a second absorption outside the operational wavelength range, wherein the second absorption is greater than the first absorption;
- coupling a waveguide with a processing light source and an operational light source, the processing light source outputting a processing light beam having a wavelength outside the operational wavelength range;
- directing the processing light beam through the waveguide to the substrate to locally heat the substrate and cause local expansion of the substrate so as to form a microlens on the substrate surface;
- and
- terminating the processing light beam to stop heating of the substrate so as to fix the microlens,
- wherein the processing light beam is diverging when it reaches the substrate.
A method for forming a microlens comprising the steps of:
- providing a substrate having a surface, the substrate having a first absorption within an operational wavelength range, and a second absorption outside the operational wavelength range, wherein the second absorption is greater than the first absorption;
- coupling a waveguide with a processing light beam having a wavelength outside the operational wavelength range;
- directing the processing light beam through the waveguide to the substrate to locally heat the substrate and cause local expansion of the substrate so as to form a microlens on the substrate surface;
- and
- terminating the processing light beam to stop heating of the substrate so as to fix the microlens,
- wherein the processing light beam is diverging when it reaches the substrate.
A method for forming a lens array comprising the steps of:
- providing a substrate having a surface, the substrate having a first absorption within an operational wavelength range, and a second absorption outside the operational wavelength range, wherein the second absorption is greater than the first absorption;
- coupling a plurality of waveguides with a processing light beam having a wavelength outside the operational wavelength range;
- and
- directing the processing light beam through the plurality of waveguides to the substrate to locally heat and expand the substrate so as to form a plurality of microlenses on the substrate surface, each of the plurality of waveguides forming a corresponding one of the plurality of microlenses.
A method for aligning a waveguide with a microlens, the method comprising:
- positioning a first end of a waveguide adjacent a glass substrate;
- coupling a second end of the waveguide with a processing light beam;
- and
- directing the processing light beam through the waveguide to locally irradiate the substrate adjacent the first end of the waveguide, the substrate being absorbing at a wavelength of the processing light beam sufficient to cause local heating and expansion of the substrate so as to form a microlens on the substrate surface adjacent and aligned with the first end of the waveguide,
- wherein the processing light beam is it reaches the substrate.
An optical assembly comprising:
- a first optical element;
- a processing light source,
- an operational light source;
- and
- a substrate having at least one microlens formed thereon by expansion of the substrate due to local heating of the substrate in a corresponding at least one location,
- wherein the first optical element is self-aligned to the at least one microlens, and the first optical element is coupled to both the processing light source and the operational light source.
Dependencies are inferred from the claim text.