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Low-cost and efficient coupling technique using reflowed sol-gel microlens

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Abstract

In this paper, we present a novel reflow technique for the fabrication of an elliptical microlens array in sol-gel glass. The fabricated refractive microlens array has a very smooth surface, and structural and dimensional conformity with the designed parameters. It is shown that the microlens array can provide high coupling efficiency of a laser diode to a single mode fiber, and relax the lateral and axial misalignment tolerance. The microlens coupling technique has the advantages of low coupling loss, large misalignment tolerances, and small package volume.

©2003 Optical Society of America

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Figures (5)

Fig. 1.
Fig. 1. Surface characterization of the 16×16 elliptical microlens array in sol-gel material (a) SEM image, (b) profile along the long-axis of elliptical aperture (unit: µm), (c) profile along the short-axis of elliptical aperture (unit: µm)
Fig. 2.
Fig. 2. Characteristic parameters of an elliptical microlens array
Fig. 3.
Fig. 3. Schematic diagram of the microlens coupling scheme
Fig. 4.
Fig. 4. Laser output power from the SMF pigtail as a function of the laser diode drive current of the two coupling methods
Fig. 5.
Fig. 5. Normalized measured coupling efficiency as a function of (a) lateral misalignment, (b) axial offset, (c) angular misalignment

Equations (4)

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R ¯ i = D i 2 + 4 h ¯ 2 8 h ¯
f ¯ i = R ¯ i ( n 1 )
F ¯ # i = f ¯ i D i
H = h ¯ ( 1 h ¯ 3 c ) 2 ( 1 h ¯ 2 c ) h ¯ 2
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