WAVELENGTH DIVISION MULTIPLEXING DEVICE WITH PASSIVE ALIGNMENT SUBSTRATE

Abstract

A wavelength division multiplexing device includes an alignment substrate configured to provide alignment between optical components of the device. The device includes a plurality of collimating lenses, and the alignment substrate includes a plurality of aligners. Each of the aligners is configured to place a respective one of collimating lenses in a predetermined position and a predetermined orientation with respect to the other collimating lenses. The alignment substrate thereby provides passive alignment of the collimating lenses with a designed optical path. The substrate may also include visual alignment markings that provide an indication of the placement of multi-layer thin film filters so that the filters define an actual optical path in alignment with the designed optical path, and integrated optical waveguides that provide an optical beam to each of the collimating lenses.

Claims

1. A wavelength division multiplexing device, comprising: a housing; a designed optical path at least partially contained within the housing; an alignment substrate associated with the housing; and a plurality of collimating lenses each having a collimator optical axis, wherein the alignment substrate includes a plurality of aligners each configured to receive a respective collimating lens of the plurality of collimating lenses such that when the respective collimating lens is received in the aligner, the collimator optical axis is aligned with the designed optical path.

2. The wavelength division multiplexing device of claim 1, wherein: the alignment substrate includes an upper surface, and each of the plurality of aligners includes a groove formed in the upper surface of the alignment substrate.

3. The wavelength division multiplexing device of claim 2, wherein the groove is V-shaped or U-shaped.

4. The wavelength division multiplexing device of claim 2, wherein: the alignment substrate further comprises a plurality of integrated optical waveguides each having a waveguide optical axis, and when the respective collimating lens is received in the aligner, the collimator optical axis is aligned with the waveguide optical axis of a respective integrated optical waveguide of the plurality of integrated optical waveguides.

5. The wavelength division multiplexing device of claim 2, wherein: the alignment substrate further includes a cavity in the upper surface that defines a lower surface, each groove formed in the upper surface of the alignment substrate includes an open end facing the cavity, and at least a portion of the designed optical path passes through the cavity.

6. The wavelength division multiplexing device of claim 1, wherein: the alignment substrate includes an upper surface, and each of the plurality of aligners includes one or more projections extending from the upper surface such that the collimator optical axis of the respective collimating lens is elevated above the upper surface of the alignment substrate.

7. The wavelength division multiplexing device of claim 6, further comprising: a plurality of optical fibers each having an end face, wherein the respective collimating lens is directly coupled to the end face of a respective optical fiber of the plurality of optical fibers.

8. The wavelength division multiplexing device of claim 7, wherein the end face of the respective optical fiber is directly coupled to the respective collimating lens by an adhesive or by welding the end face to the respective collimating lens.

9. The wavelength division multiplexing device of claim 1, wherein: each of the plurality of collimating lenses includes an abutment, each of the plurality of aligners includes a stop, and each of the plurality of collimating lenses is placed in a respective predetermined position along the designed optical path when the abutment of the collimating lens is in contact with the stop of the aligner.

10. The wavelength division multiplexing device of claim 1, further comprising: at least one filter that defines an actual optical path for an optical beam, wherein the at least one filter is configured to receive the optical beam from a first collimating lens of the plurality of collimating lenses, transmit at least a first portion of the optical beam toward a second collimating lens of the plurality of collimating lenses, and reflect at least a second portion of the optical beam toward a third collimating lens of the plurality of collimating lenses.

11. The wavelength division multiplexing device of claim 10, wherein the alignment substrate further includes one or more alignment markings that provide an indication of a placement of the at least one filter on the alignment substrate such that the actual optical path of the optical beam is aligned with the designed optical path.

12. (canceled)

13. (canceled)

14. A method of making a wavelength division multiplexing device including a plurality of collimating lenses each having a collimator optical axis aligned with a designed optical path, the method comprising: providing an alignment substrate having a plurality of aligners, each of the plurality of aligners configured to receive a respective collimating lens of the plurality of collimating lenses; and placing each of the plurality of collimating lenses in a respective aligner of the plurality of aligners, wherein each of the plurality of collimating lenses has a collimator axis that is aligned with the designed optical path after the collimating lens is placed in the respective aligner; placing the alignment substrate at least partially within the housing such that the designed optical path is at least partially contained within the housing.

15. The method of claim 14, wherein: the alignment substrate includes a plurality of integrated optical waveguides in or on the alignment substrate each including a waveguide optical axis, and placing each of the plurality of collimating lenses in the respective aligner aligns the collimator optical axis of the respective collimating lens with the waveguide optical axis of a respective integrated optical waveguide of the plurality of integrated optical waveguides.

16. The method of claim 14, wherein each collimating lens of the plurality of collimating lenses includes an abutment, each aligner of the plurality of aligners includes a stop, and the method further comprises: abutting the abutment of the respective collimating lens with the stop of the respective aligner, wherein abutting the abutment with the stop positions the respective collimating lens along the designed optical path.

17. The method of claim 14, further comprising: placing at least one filter that defines an actual optical path for an optical beam on the alignment substrate, wherein the at least one filter is configured to receive the optical beam from a first collimating lens of the plurality of collimating lenses, transmit at least a first portion of the optical beam toward a second collimating lens of the plurality of collimating lenses, and reflect at least a second portion of the optical beam toward a third collimating lens of the plurality of collimating lenses.

18. The method of claim 17, wherein the alignment substrate further includes one or more alignment markings that provide an indication of a placement of the at least one filter on the alignment substrate such that the actual optical path of the optical beam is aligned with the designed optical path, and further comprising: aligning the at least one filter with a respective alignment mark of the one or more alignment marks.

19. The method of claim 14, wherein the alignment substrate further includes a cavity in the upper surface that defines a lower surface, and at least a portion of the designed optical path passes through the cavity.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The accompanying drawings are included to provide a further understanding and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiment(s), and together with the description serve to explain principles and operation of the various embodiments. Features and attributes associated with any of the embodiments shown or described may be applied to other embodiments shown, described, or appreciated based on this disclosure.

[0033] FIG. 1 is a top view of an exemplary WDM device including a plurality of filters and collimators;

[0034] FIG. 2 is a graphical view depicting changes in the center frequency of a filter of the WDM device of FIG. 1 in response to different angular offsets from the normal angle of incidence;

[0035] FIG. 3 is a diagrammatic cross-sectional view of a collimator of the WDM device of FIG. 1;

[0036] FIG. 4 is a diagrammatic cross-sectional view of another type of collimator that may be used in a WDM device which includes an alignment substrate;

[0037] FIG. 5 is a diagrammatic view of an exemplary alignment substrate for a WDM device;

[0038] FIG. 6 is a diagrammatic view of a WDM device including the alignment substrate of FIG. 5;

[0039] FIG. 7 is a diagrammatic view of a WDM device including another exemplary alignment substrate;

[0040] FIG. 8 is a diagrammatic view of another exemplary alignment substrate including a plurality of integrated optical waveguides and alignment grooves;

[0041] FIG. 9 is a diagrammatic view of a WDM device including the alignment substrate of FIG. 8;

[0042] FIG. 10 is a perspective view of a portion of the alignment substrate of FIG. 8;

[0043] FIGS. 11-14 are cross-sectional views of various exemplary grooves that may be used in the alignment substrates of FIGS. 5 and 8;

[0044] FIGS. 15A-17D are perspective views of various exemplary alignment features that may be used to provide aligners in the alignment substrates of FIGS. 5 and 8.

DETAILED DESCRIPTION

[0045] Various embodiments will be further clarified by examples in the description below. In general, the description relates to WDM devices that include a substrate configured to passively align one or more optical components of the WDM device. The WDM devices may also use collimators that all have the same fixed working distance, e.g., d.sub.wD=0. Eliminating the need for an adjustable working distance may allow elimination of the air gap 58 applied in conventional collimators 40, such as depicted by FIG. 3. This may allow collimators to be reduced to only two components, a fiber and a collimating lens that transforms the diameter of the optical beam, or in some embodiments, just the collimating lens. The diameter of the optical beam may be adjusted such that the focusing effect of the curved surface of the filters compensates for diffractive beam widening.

[0046] FIG. 4 depicts an exemplary collimator 70 (sometimes referred to as a “fiber collimator” or “pigtail collimator”) including a collimating lens 72 operatively coupled to an optical fiber 74. The collimating lens 72 includes an optical axis 75, a cylindrical surface 76, a waveguide interface surface 78, and an air interface surface 80. The waveguide interface surface 78 is joined to the air interface surface 80 by the cylindrical surface 76, and oriented at a generally orthogonal angle relative to the optical fiber 74. One end of the optical fiber 74 may be directly coupled to the waveguide interface surface 78 of collimating lens 72 by an adhesive 82 (shown) or by welding/fusing an end of the optical fiber 74 to the waveguide interface surface 78, e.g., by laser processing or an electric arc. The collimating lens 72 may be configured (e.g., by choice of refractive index, length, and radius of curvature of the air interface surface 80) so that the waist 84 of an optical beam 86 emitted by the collimator 70 is located at or proximate to the air interface surface 80. This may result in the collimator 70 having a working distance d.sub.wD=0.

[0047] Eliminating the air gap between the collimating lens 72 and optical fiber 74 may avoid the need for a housing or ferrule. Directly coupling the collimating lens 72 to the optical fiber 74 may also produce a more accurate alignment between the optical axis 75 of collimating lens 72 and the optical fiber 74 associated with the collimating lens 72. Eliminating the collimator housing may also avoid introducing mechanical tolerances that can be a source of misalignments between the collimating lens 72 and the other optical components of the WDM device. This improvement in alignment may be due to the orientation of the collimating lens 72 within the WDM device being defined by the cylindrical surface 76 of the collimating lens 72 rather than by, with reference to FIG. 3, how accurately the collimating lens 42 and ferrule 46 are aligned with each other as well as the housing 44. Both the direct coupling of the collimating lens 72 to the optical fiber 74 and the elimination of the collimator housing 44 may reduce pointing angle misalignment as compared to the collimator 40 depicted by FIG. 3. Elimination of the collimator housing 44 may also facilitate alignment between the collimating lens 72 and one or more passive alignment features, as described in detail below.

[0048] Advantageously, the exemplary collimator 70 provides a simplified collimator structure that contributes to improved collimator quality and accuracy by avoiding the variations introduced by use of an air gap, housing, ferrule, and angled interfaces. The exemplary collimator 70 also avoids the need for anti-reflection coatings on the end-faces of the collimating lens 72 and optical fiber 74, naturally provides improved alignment between the optical fiber 74 and collimating lens 72, reduces pointing angle errors, working distance offsets, and lowers the manufacturing cost of the collimator 70. Once a relation between the cylindrical surface 76 of collimating lens 72 and the direction of the optical beam 86 is determined, alignment features may be defined with predetermined positions and orientations on a substrate such that each of the collimators 70 will be properly aligned upon assembly of the WDM device.

[0049] FIGS. 5 and 6 provide top-views depicting an alignment substrate 90 (FIG. 5) and an exemplary free-space three-port WDM device 92 (FIG. 6). The WDM device 92 includes a filter 12, the alignment substrate 90, a common port collimator 96 that functions as a common port, a transmission port collimator 97 that functions as a transmission port, and a reflection port collimator 98 that functions as a reflection port. The alignment substrate 90 includes an upper surface 100, a cavity 102 that defines a lower surface 104 offset from the upper surface 100, and a plurality of alignment features (“aligners”) 106 each comprising a groove (e.g., a V-shaped groove) having a distal end open to the cavity 102. The lower surface 104 may include visual alignment markings 108 indicative of a placement for the filter 12. Each aligner 106 may be configured to receive the collimating lens 72 of a respective collimator 96-98, and to align each collimator 96-98 so that the optical beam 86 follows a designed optical path 109 between the filter 12 and collimators 96-98. The aligners 106 may be fabricated, for example, using photolithography, high-precision milling, laser processing, or any other suitable technique.

[0050] The WDM device 92 represents a WDM device according to this disclosure in its simplest form. When operating in a demultiplexing mode, the optical beam 86 is launched from the common port collimator 96 towards the filter 12. A portion of the optical beam 86 may be transmitted by the filter 12 and received by the transmit port collimator 97. The remainder of the optical beam 86 may be reflected toward and received by the reflection port collimator 98. Both the collimators 96-98 and the aligners 106 can be made with high precision, so that only the filter 12 requires active alignment.

[0051] The optimal position and orientation of the filter 12 may be driven by the positions of the common and reflection port collimators 96, 98. However, variations of the surface curvature of the filters 12 may require active alignment of each filter 12. In cases where the position of the reflection port is fixed (such as depicted by FIG. 6), it may only be possible to optimize one of insertion loss or center wavelength shift at a time through alignment of the filter 12. In this type of WDM device, a compromise may be found that minimizes the impact on overall performance by balancing insertion loss and center wavelength shift. This type of filter arrangement may therefore be more suitable for CWDM than for DWDM since the filter bandwidth is much wider for CWDM, e.g., about 0.7 nm for DWDM vs. 20 nm for CWDM filters at full-width half-maximum. CWDM devices may therefore be more tolerant of center wavelength shift. To improve performance (e.g., for DWDM applications), an additional adjustable optical element such as a wedge or a lens (not shown) may be inserted into the optical path to provide an additional degree of freedom to the design.

[0052] Manufacturing tolerances of the filters 12 may be compensated for by active alignment of the filters 12. To optimize coupling between the optical beam 86 and the optical fiber 74 on the reflection port, the filter 12 may be moved laterally (as depicted by double arrowed line 88) and along the optical beam 86 (left-right as depicted by double arrowed line 89) without affecting the coupling between the optical beam 86 and the optical fiber 74 on the transmission port. Any rotation of the filter 12 may change the lateral shift position of the optical beam 86 in the plane of the transmission port, which can affect coupling between the optical beam 86 and optical fiber 74 at the transmission port.

[0053] FIG. 7 depicts an exemplary free-space multi-port device 110 including a plurality of filters 12, collimators 70, a housing 111, and an alignment substrate 112 associated with the housing 111 and having a plurality of aligners 106 and visual alignment markings 108. The alignment substrate 112 may be associated with the housing 111, for example, by operatively coupling the alignment substrate 112 to the housing 111 (e.g., using fasteners or adhesive), or by forming alignment substrate 112 as an integral part of the housing 111 (e.g., by machining or molding the housing 111 and alignment substrate 112 as a single unit). For WDM devices in which the filters 12 are angled (such as depicted by FIGS. 6 and 7), the aligners 106 for the common and transmission port collimators 70 may be laterally shifted with respect to each other as the optical beam 86 experiences a lateral shift by refraction at the surfaces of the filters 12.

[0054] For a WDM device in which all the collimators have a working distance d.sub.wD=0, the performance of the WDM device may be relatively tolerant to collimating lens alignment errors along the length of the optical path. That is, only the lateral position of the collimator lenses 72 may require high precision, which may be provided, for example, by linear indentations into the substrate (e.g., V-shaped grooves) or projections (e.g., parallel walls or linearly spaced pylons). High precision structures can be fabricated using photolithography, high-precision milling, laser processing, or any other suitable technique.

[0055] FIGS. 8 and 9 provide top-views depicting an exemplary alignment substrate 120 (FIG. 8) and free-space multi-port WDM device 122 (FIG. 9). The WDM device 122 includes a plurality of filters 12, a plurality of collimating lenses 72, a housing 124 associated with the alignment substrate 120, and a plurality of integrated optical waveguides 126. Each integrated optical waveguide 126 may be configured to couple an optical beam comprising one or more optical signals between an optical connector 128, 130 and a respective collimating lens 72. The integrated optical waveguides 126 may be fabricated, for example, using a multi-step process including one or more sub-processes, such as deposition, photolithography, ion exchange, etching, or laser writing, or by any other suitable means. The alignment substrate 120 may include an upper surface 132, a cavity 134 that defines a lower surface 136 offset from the upper surface 132, and a plurality of aligners 138. Each aligner 138 may comprise a groove (e.g., a V-shaped groove) having a distal end open to the cavity 134.

[0056] FIG. 10 is a perspective view of a portion of the alignment substrate 120 showing details of exemplary aligners 138. Each aligner 138 comprises a groove 140 including diagonal surfaces 142 arranged in a V-shape, an open end 144 facing the cavity 134, and a closed end 146 opposite the open end 144. The groove 140 may have a length such that, when the waveguide interface surface 78 of collimating lens 72 abuts the closed end 146 of groove 140, the collimating lens 72 is aligned linearly along the optical path of the WDM device 122. Thus, the interface surface 78 of collimating lens 72 may provide an abutment 147 and the closed end 146 of groove 140 may provide a stop 149. The abutment 147 and stop 149 may cooperate to position the collimating lens 72 along the designed optical path 109 when the abutment 147 of the collimating lens 72 is in contact with the stop 149 of the aligner 138. The diagonal surfaces 142 of the groove 140 are configured to position the collimating lens 72 so that its optical axis 75 is aligned laterally (vertically and horizontally) and angularly with both the end face of the integrated optical waveguide 126 associated with the aligner 138 and the optical path of WDM device 122. This placement may be achieved through contact between the diagonal surfaces 142 of groove 140 and the cylindrical surface 76 of collimating lens 72.

[0057] FIGS. 11 and 12 provide cross-sectional views of the V-shaped groove 140 and an exemplary stepped groove 148. The stepped groove 148 includes steps 150 each having a corner 152 that supports the culminating lens 72. Each of the grooves 140, 148 is configured to position the collimating lens 72 vertically and horizontally through contact with its cylindrical surface 76 such that the optical axis 75 of the collimating lens 72 is aligned with both the integrated optical waveguide 126 and the optical path. This alignment may be accomplished by configuring each groove 140, 148 to contact the cylindrical surface 76 of collimating lens 72 along two points of contact, e.g., lines of contact with the diagonal surfaces 142 of groove 140 or the corners 152 of each step 150 of groove 148.

[0058] FIGS. 13 and 14 provide cross-sectional views of another V-shaped groove 154 and an exemplary raised groove 156. The raised groove 156 may comprise a pair of parallel steps 158 that project upward from the upper surface 132 of alignment substrate 120. Each of the grooves 154, 156 is configured to position the collimating lens 72 vertically and horizontally through contact with its cylindrical surface 76 so that the optical axis 75 of the collimating lens 72 is above the upper surface 132 of alignment substrate 120. This may provide clearance to accommodate the optical fiber 74 for embodiments in which the optical fiber 74 is directly coupled to the waveguide interface surface 78 of collimating lens 72. This raised vertical positioning of the collimating lenses 72 may also allow omission of the cavity 102 by raising the optical path of the WDM device 122 above the upper surface 132 of alignment substrate 120.

[0059] FIGS. 15A and 15B are perspective views of a portion of two embodiments of an alignment substrate 160 including a top surface 162 and exemplary aligners 164 each including the raised groove 156 of FIG. 14. Each aligner 164 may include a pair of parallel steps 158, with the embodiment depicted by FIG. 15A also including a cross-step 166 that joins the proximal ends of the parallel steps 158. When present, the cross-step 166 may provide a stop 168 that aligns the collimating lens 72 along the predetermined optical path of the optical beam 86. Each parallel step 158 may provide a point of contact 169 in the form of an edge that contacts the cylindrical surface 76 of collimating lens 72.

[0060] FIG. 16 is a perspective view of a portion of an alignment substrate 170 including a top surface 172 and exemplary aligners 174 having a similar configuration as the aligners 164 of FIG. 15A, but with a portion of each parallel step 158 between the proximal and distal ends thereof omitted. The resulting aligner 174 includes a pair of forward supports 176 and a rear support 178. Each forward support 176 may comprise a column that projects upward from the top surface 172 of alignment substrate 170, and which provides a point of contact 180 with the cylindrical surface 76 of collimating lens 72. The forward supports 176 may thereby cradle a portion of the cylindrical surface 76 of collimating lens 72 proximate the air interface surface 80 thereof. The rear support 178 may include the cross-step 166 of FIG. 15A to align the collimating lens 72 along the optical path, and projections 182 each providing a point of contact 184 with the cylindrical surface 76 of collimating lens 72. The projections 182 may operate cooperatively with the forward supports 176 to define the orientation of the collimating lens 72 such that the optical axis 75 thereof is aligned with the optical path.

[0061] FIGS. 17A-17D are perspective views of a portion of an alignment substrate 190 including a top surface 192 and exemplary aligners 194. Each aligner 194 includes a plurality of supports, including the forward supports 176 and rear supports 196. Each rear support 196 comprises a column that projects upward from the top surface 192 of alignment substrate 190 and which provides a point of contact 202 with the cylindrical surface 76 of collimating lens 72. The embodiments depicted by FIGS. 17A-17C also include one or more stops 198. Each stop 198 provides a surface 200 which aligns the collimating lens 72 along the predetermined optical path. The stop 198 of FIG. 17B includes a groove 204 (e.g., a U-shaped groove) to accommodate the optical fiber 74 and/or the adhesive 82 depicted by FIG. 4. The stops 198 depicted by FIG. 17C are arranged to provide a gap 206 between the stops 198 to accommodate the optical fiber 74 and/or adhesive 82.

[0062] Advantages provided by aligner substrates may include simplification of the free-space WDM device assembly (thereby reducing the required assembly time), elimination of the need for active collimator alignment, lower WDM device cost, reduced component cost (e.g., simplified collimators), reduced WDM device size, and elimination of the need to accommodate optical fiber bend radiuses for embodiments using integrated optical waveguides 126.

[0063] While the present disclosure has been illustrated by the description of specific embodiments thereof, and while the embodiments have been described in considerable detail, it is not intended to restrict or in any way limit the scope of the appended claims to such detail. The various features discussed herein may be used alone or in any combination within and between the various embodiments. Additional advantages and modifications will readily appear to those skilled in the art. The present disclosure in its broader aspects is therefore not limited to the specific details, representative apparatus and methods and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope of the present disclosure.