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

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.