Microlens passive alignment apparatus and method of use

Abstract

A method and apparatus for passively aligning microlenses and other optical elements and devices is disclosed herein. The method taught herein is particularly well suited to effect the passive alignment of cylindrical microlenses with other elements or devices, such as laser diodes. Cylindrical microlens structures formed in accordance with the principles of the present invention use a base substrate having one or more alignment sites. The alignment sites being formed using wafer scale fabrication techniques are formed with a high degree of precision, such that cylindrical microlenses fitted into the alignment sites are aligned with respect to each other and are positioned a proper optical distance from each other. These microlens structures can be constructed individually or constructed en masse enabling mass production of the microlens structures. Moreover, the microlens structures can be passively aligned with other optical elements. This can be effectuated by urging the optical element into intimate mechanical contact with an alignment member mounted on a microlens, thereby passively aligning the optical element with the microlens structure. This enables the fabrication of micro-optical devices using a minimum of skilled labor and achieving a superior degree of optical perfection.