Method for Precision Clamp and Alignment of Optical Fibers During Lens Grinding Operations

Abstract

Systems and methods are disclosed for clamping an optical fiber for lens grinding by inserting an optical fiber into an optical fiber core dimension matching ferrule tube; aligning the optical fiber using a rotatable optical fiber guide tube; engaging a front optical fiber clamp mechanism to secure a front portion of the optical fiber; engaging a rear optical fiber clamp mechanism to secure a rear portion of the optical fiber; and performing a lens grinding operation on an end of the optical fiber. The method is tailored for working with multiple fibers simultaneously and also supports precise alignment for polarization-maintaining fibers. This innovation streamlines the formation of lens-equipped fiber ends, boosting production efficiency and lens quality.

Description

[0001] The present invention is related to co-pending commonly filed Application Ser. No. 19 / 060,496 on Feb. 21, 2025, the content of which is incorporated by reference.BACKGROUND OF THE INVENTION

[0002] Fiber lenses are used in telecom pump systems and fiber lasers. Fiber lenses are used in telecom pump systems and fiber lasers. These applications require high-precision optical components to ensure optimal performance and efficiency. Traditionally, aligning and clamping optical fibers for lens grinding purposes has been plagued with challenges such as maintaining consistent pressure, preventing fiber damage, and ensuring precise orientation throughout the grinding process.

[0003] As optical fiber applications proliferate in telecommunications, medical imaging, and sensor technology, the demand for efficient and precise lens production has intensified.SUMMARY OF THE INVENTION

[0004] In one aspect, the method involves a series of steps to secure an optical fiber for lens grinding. Initially, the optical fiber is inserted into a ferrule tube designed to match the core dimension of the fiber. A rotatable guide tube is then used to align the fiber accurately. Subsequent to alignment, both the front and rear portions of the fiber are clamped securely in place using respective front and rear clamp mechanisms. With the fiber thus secured, a lens grinding operation is performed on the end of the optical fiber.

[0005] In another aspect, a method for clamping an optical fiber for lens grinding includes inserting an optical fiber into an optical fiber core dimension matching ferrule tube; aligning the optical fiber using a rotatable optical fiber guide tube; engaging a front optical fiber clamp mechanism to secure a front portion of the optical fiber; engaging a rear optical fiber clamp mechanism to secure a rear portion of the optical fiber; and performing a lens grinding operation on an end of the optical fiber. The method is tailored for working with multiple fibers simultaneously and also supports precise alignment for polarization-maintaining fibers. This innovation streamlines the formation of lens-equipped fiber ends, boosting production efficiency and lens quality.

[0006] Advantages of the precise clamping and alignment of the fibers during lens grinding may include, but are not limited to:

[0007] Precision Alignment: The use of a rotatable guide tube allows for meticulous orientation of the optical fiber, which is crucial for achieving the desired curvature and smoothness on the lens surface. Precision alignment ensures that optical performance is not compromised due to misalignment during the grinding process.

[0008] Reduced Fiber Damage: The design of the clamping mechanisms (both front and rear) are optimized to hold the optical fiber securely without exerting excessive pressure that could potentially damage the fiber. This feature is critical, as any damage to the fiber could degrade the overall performance of the optical device.

[0009] Consistent Clamping Pressure: One implementation may provide a uniform clamping force across the front and rear portions of the fiber, which is essential for maintaining the integrity of the fiber during grinding and prevents unwanted movement that could affect the grinding quality.

[0010] Enhanced Production Throughput: By streamlining the lens grinding process through effective clamping and alignment, production efficiency is significantly improved. The system could allow for faster setup times, reduced cycle times, and the potential for automated processing.

[0011] Improved End-Product Quality: With the fiber held steadily in place and accurately aligned, the resulting ground lens is likely to be of higher quality, with better optical properties and fewer defects. This directly translates to enhanced performance in the various applications where optical fibers are utilized, such as telecommunications, medical instruments, and sensor technologies.

[0012] Adaptability to Different Core Dimensions: The use of a ferrule tube designed to match the core dimension of the fiber suggests that the system could be adaptable to fibers of various sizes, thereby increasing its utility across a wide range of optical fiber specifications.

[0013] Potential for Automated Processes: The design may lend itself to automation, allowing for the integration of robotic systems to handle the optical fibers, align, clamp, and grind the lenses without or with minimal human intervention. This automation could lead to higher precision and repeatability in large-scale manufacturing environments.

[0014] By utilizing the rotatable optical fiber guide tube, adjustments can be made to the fiber's orientation within the setup, facilitating this precise alignment. The clamps at both ends of the fiber, namely the rear optical fiber clamp and the front optical fiber clamp, secure the fiber in place once the alignment is achieved. These clamps incorporate both elastic and push-to-clamp mechanisms, each with a dedicated locking feature, to ensure minimal movement and maximum stability during the lens grinding process. This dual-clamping approach effectively minimizes any rotational shifts, thus preserving the precise alignment of the stress rods.

[0015] The above impacts on production efficiency, quality control, and the technological performance of optical fiber-based products. The enhanced clamping and alignment of optical fibers during lens grinding can significantly improve production throughput and the quality of the end-product, addressing a critical need within the optical manufacturing industry.BRIEF DESCRIPTION OF DRAWINGS

[0016] FIGS. 1A-1C show a system with a rear optical fiber clamp, an optical fiber guide tube, and a front optical fiber clamp.

[0017] FIG. 2A-2B show illustrations of an exemplary fiber optical ferrule tube and an adapter.

[0018] FIG. 3 shows an exemplary flowchart depicting the process of inserting, aligning, clamping, and performing lens grinding on an optical fiber.

[0019] FIG. 4 shows an exemplary flowchart showing the securing of the optical fiber.

[0020] FIG. 5 shows an exemplary process of disengaging the optical fiber in its assembly.DETAILED DESCRIPTION OF THE INVENTION

[0021] FIGS. 1A-1C illustrate a system for securing an optical fiber during lens grinding. The system includes a rear optical fiber clamp 110, an optical fiber guide tube 120, and a front optical fiber clamp 130. Initially, the optical fiber is inserted into a ferrule tube designed to match the core dimension of the fiber. The system includes a mechanism for handling a polarization-maintaining optical fiber, ensuring precision and accuracy in alignment. A rotatable guide tube is employed to ensure precise alignment of the optical fiber. This alignment is essential for optimal performance during the subsequent lens grinding operation. Once aligned, the front portion of the optical fiber is secured in place using a front optical fiber clamp 130, while the rear portion is similarly secured with a rear optical fiber clamp mechanism 110. This secure clamping allows for accurate and efficient grinding of a lens on the fiber end.

[0022] In FIGS. 1A-1C, the front optical fiber clamp 130 holds the front portion of the optical fiber in place. It ensures that the fiber remains precisely aligned during a lens grinding operation, preventing any potential movement that could lead to misalignment or defects in the fiber's end surface. The front optical fiber clamp 130 contributes to maintaining the stability and accuracy required for optimal optical performance. A rear Optical Fiber Clamp 110 secures the rear portion of the optical fiber, ensuring stability during the grinding process. An Optical Fiber Guide Tube 120 is a rotatable tube that allows precise alignment of the optical fiber, and for achieving the desired lens curvature and surface smoothness. The rear and front clamps incorporate both elastic and push-to-clamp mechanisms, each equipped with a dedicated locking feature. This dual-clamping approach minimizes rotational shifts, preserving the precise alignment of the fiber, which is particularly critical for polarization-maintaining fibers.

[0023] FIGS. 2A-2B showcase the fiber optical ferrule tube and adapter combination 220. The combination includes a Fiber Ferrule 222 which is a rigid tube designed to confine the stripped end of the optical fiber, providing mechanical alignment and protection. The ferrule tube confines and protects the stripped end of an optical fiber. It is a rigid tube specifically engineered to match the core dimension of the fiber, providing precise mechanical alignment and safeguarding the delicate fiber structure. By housing the fiber core with precision, the ferrule tube ensures that the fiber core remains centered and stable during the lens grinding / formation process. This precise fit is essential for maintaining the integrity of the optical fiber while enabling accurate positioning required for high-quality lens production. The ferrule tube works in conjunction with other system components, such as the rotatable optical fiber guide tube and adapter, to facilitate fine adjustments and precise manipulation of the fiber during the grinding operation.

[0024] The ferrule tube 222 works in conjunction with other components of the system, such as the optical fiber guide tube and adapter 224, to provide a secure and adjustable holding system. This setup maintains the integrity of the delicate optical fiber while enabling the precise positioning required for high-quality lens production.

[0025] The Ferrule Adapter 224 works in conjunction with the ferrule tube 222 to ensure a precise fit for the fiber by matching its core dimensions. The ferrule tube is designed to match the core dimensions of the optical fiber, ensuring secure holding and precise alignment. The adapter allows for fine adjustments and precise manipulation of the fiber during the lens grinding operation. This adapter is designed to connect with the rotatable optical fiber guide tube, allowing for fine adjustments and precise manipulation of the optical fiber during the lens grinding operation. By facilitating the rotation of the guide tube along its axis, the adapter enables meticulous orientation of the fiber, which is essential for achieving the desired curvature and smoothness on the lens surface. The ferrule adapter 224 effectively bridges the gap between the stationary ferrule tube and the dynamic guide tube, providing a secure yet adjustable holding system that maintains the integrity of the delicate optical fiber while enabling the precise positioning required for high-quality lens production.

[0026] The above clamping approach enhances the lens grinding process in several ways. Precision Alignment is achieved as the rotatable guide tube allows for precise orientation of the optical fiber and for achieving the desired curvature and smoothness on the lens surface. The dual-clamping system, utilizing both front and rear clamps, ensures the fiber remains stable throughout the grinding process, preventing unwanted movement that could affect grinding quality. The clamping mechanisms are optimized to hold the optical fiber securely without exerting excessive pressure, minimizing the risk of fiber damage. The system can accommodate fibers of various sizes, increasing its utility across a wide range of optical fiber specifications. By streamlining the lens grinding process through effective clamping and alignment, production efficiency is significantly improved. The system allows for faster setup times, reduced cycle times, and the potential for automated processing. With the fiber held steadily in place and accurately aligned, the resulting ground lens is likely to be of higher quality, with better optical properties and fewer defects. This directly translates to enhanced performance in various applications such as telecommunications, medical instruments, and sensor technologies. The system's ability to process multiple optical fibers simultaneously using multiple sets of front and rear optical fiber clamp mechanisms greatly increases production capacity. This parallel configuration optimizes workflow and reduces overall processing time. The design ensures that the characteristics and integrity of each optical fiber are maintained throughout the grinding process, providing a non-destructive method that enhances the reliability and performance of the optical fibers post-processing.

[0027] These benefits collectively address critical needs within the optical manufacturing industry, significantly improving production throughput, quality control, and the technological performance of optical fiber-based products.

[0028] FIG. 3 illustrates the process of inserting, aligning, clamping, and performing lens grinding on an optical fiber. Viewing FIG. 1 and FIG. 3 together, the method of FIG. 3 begins with inserting an optical fiber into a ferrule tube that matches the core dimensions of the fiber. This step, labeled as S100, ensures that the optical fiber is held securely and supports subsequent precise alignment and secure clamping, which help in the lens grinding operation that follows.

[0029] The process of aligning the optical fiber utilizes a rotatable optical fiber guide tube. This step ensures the fiber is oriented with precision, a crucial aspect for obtaining the desired curvature and smoothness of the lens surface during subsequent grinding operations. The guide tube's ability to rotate allows for meticulous alignment, which is vital for maintaining optimal optical performance and preventing any misalignment issues that could compromise the quality of the final product.

[0030] The method involves engaging a front optical fiber clamp 130 to securely hold the front portion of the optical fiber. This step maintains the fiber's stability during subsequent processing steps. Proper clamping ensures that the optical fiber remains precisely positioned, which is necessary for the accurate execution of the lens grinding operation on the fiber's end. This precise fixation mitigates the risk of misalignment and contributes to the overall quality and precision of the lens surface.

[0031] The method involves engaging a rear optical fiber clamp 110 to securely hold the rear portion of the optical fiber in place. This step ensures that the optical fiber remains stable during subsequent operations, reducing movement and enhancing the precision of the lens grinding process. By firmly securing the fiber at both the front and rear, the setup mitigates any potential alignment issues that could affect the quality of the final lens curvature and smoothness.

[0032] Once secured, the system can perform the lens grinding operation on an end of the optical fiber, in S108. This step follows the precise securing of both the front and rear portions of the optical fiber using respective clamp mechanisms. This operation is used for ensuring the optical fiber achieves optimal lens curvature and surface smoothness, for effective light transmission. The grinding is executed once the fiber is securely aligned and clamped, minimizing potential misalignment and ensuring quality optical performance. The grinding process is conducted with the fiber held firmly, ensuring that the intended curvature and surface smoothness are achieved, for optimal optical performance.

[0033] This mechanism is particularly advantageous in applications where precision is needed, as it minimizes the risk of misalignment that could otherwise lead to suboptimal lens formation or damage to the fiber. The rotary movement provided by the drive mechanism allows the optical fiber to be adjusted while maintaining secure clamping from both the rear optical fiber clamp 110 and the front optical fiber clamp 130, which include an elastic clamp holding mechanism and a push-to-clamp holding mechanism. These clamps provide robust support to the fiber, ensuring it remains stationary during alignment adjustments and lens processing.

[0034] FIG. 2 illustrates a fiber optical ferrule tube and an adapter. The optical fiber guide tube can be rotated along the tube axis by a rotary drive motor or suitable mechanism. The optical fiber core dimension matching ferrule tube holds the end of the optical fiber where the lens will be ground. The tube and adapter functions to ensure a precise fit for the fiber by matching its core dimensions. This precise matching is essential for maintaining the fiber's alignment and stability during the grinding process. The ferrule tube works in conjunction with an optical fiber guide tube, which can be rotated along its axis using a rotary drive motor or mechanism. This rotatable guide tube serves as an adaptor, allowing for fine adjustments and precise manipulation of the fiber during the lens grinding operation. Together, these components provide a secure and adjustable holding system that maintains the integrity of the delicate optical fiber while enabling the precise positioning required for high-quality lens production.

[0035] As used herein, the term “ferrule” is intended to mean a rigid tube used to confine the stripped end of an optical fiber, providing mechanical alignment and protection for the fiber. The ferrule used in the present method is specifically designed to house the fiber core with precision, ensuring that the fiber core is centered and stable when a lens is formed on its end by the grinding process.

[0036] Due to the optical fiber core dimension matching, the optical ferrule tube securely holds the end of the optical fiber. The tube ensures precise alignment by matching the fiber's core dimensions, facilitating effective lens grinding operations.

[0037] After the optical fiber is placed into the ferrule tube, a rotatable guide tube is employed to fine-tune the alignment of the fiber, allowing for positional adjustments. This step ensures that subsequent grinding creates a lens surface that is free of imperfections and meets rigorous standards for optical performance. Once aligned, the front and rear portions of the fiber are fixed using dedicated clamp mechanisms that are designed to hold the fiber securely without damaging it.

[0038] FIG. 4 illustrates the process for engaging the fiber with the following operations: activating an elastic clamp holding mechanism (S200), activating a push-to-clamp holding mechanism (S202), and engaging a locking mechanism (S204).

[0039] The process of activating an elastic clamp holding mechanism, denoted as step S200, involves securing an optical fiber using an elastic element. This step is crucial for maintaining the fiber in a stable position during subsequent operations, ensuring that precise alignment is not disturbed. The elastic clamp provides adaptable pressure, accommodating variations in fiber diameter while maintaining a firm grip.

[0040] Step S202 involves the activation of a push-to-clamp holding mechanism designed to secure the optical fiber in place efficiently. This mechanism provides a consistent and reliable grip, which is crucial for maintaining the fiber's position during the subsequent lens grinding operation, thereby ensuring precision and stability throughout the process.

[0041] The engaging a locking mechanism step, designated as S204, involves the activation of a component designed to firmly secure parts of the apparatus in a fixed position during the process. This ensures stability and precision during the operation, crucial for maintaining the alignment and integrity of the optical fiber setup.

[0042] The releasing the front and rear optical fiber clamp is detailed next in FIG. 5. The process includes disengaging the locking mechanisms (S700); deactivating the push-to-clamp holding mechanisms (S702); and deactivating the elastic clamp holding mechanisms (S704). The process begins with the step of disengaging the locking mechanisms, identified as S700. This action iniates the release of the previously secured optical fiber components, ensuring the system transitions smoothly to the next stage of the deactivation sequence.

[0043] Next, in S702, the push-to-clamp system that had been used to secure the optical fiber during the grinding operation is released. This step follows the disengagement of the locking mechanisms, ensuring that the optical fiber is no longer held by the push-to-clamp system, thus preparing it for subsequent operations or removal.

[0044] In S704, the elastic clamps that were previously engaged to secure the optical fiber during the lens grinding procedure are released. This step is part of the sequence to ensure the optical fiber is safely detached from the apparatus without causing misalignment or damage, following the successful completion of the grinding operation.

[0045] One implementation further includes a capability for processing multiple optical fibers simultaneously by utilizing multiple sets of front and rear optical fiber clamp mechanisms. Each optical fiber is inserted into its respective optical fiber core dimension matching ferrule tube, ensuring precise alignment specific to each fiber's geometry. The optical fiber guide tubes, which can rotate along their tube axes via rotary drive mechanisms, facilitate the alignment process for each individual fiber. The system employs multiple front optical fiber clamp mechanisms, each comprising an elastic clamp holding mechanism, a push-to-clamp holding mechanism, and a locking mechanism. These components work in concert to secure the front portion of each optical fiber firmly within its setup, preventing unwanted movement during processing. Similarly, the rear optical fiber clamp mechanisms, also equipped with elastic and push-to-clamp holding mechanisms along with a locking mechanism, ensure the rear portion of each optical fiber is adequately secured. This parallel configuration allows for efficient processing of multiple fibers, optimizing workflow and reducing processing time. The design ensures that the characteristics and integrity of each optical fiber are maintained, providing a nondestructive method that enhances the reliability and performance of the optical fibers post-processing.

Claims

1. A method for clamping an optical fiber for lens grinding, comprising:inserting an optical fiber into an optical fiber core dimension matching ferrule tube;aligning the optical fiber using a rotatable optical fiber guide tube;engaging a front optical fiber clamp mechanism to secure a front portion of the optical fiber;engaging a rear optical fiber clamp mechanism to secure a rear portion of the optical fiber; andperforming a lens grinding operation on an end of the optical fiber.

2. The method of claim 1, wherein engaging the front optical fiber clamp mechanism comprises:activating an elastic clamp holding mechanism;activating a push-to-clamp holding mechanism;engaging a locking mechanism.

3. The method of claim 1, wherein engaging the rear optical fiber clamp mechanism comprises:activating an elastic clamp holding mechanism;activating a push-to-clamp holding mechanism;engaging a locking mechanism.

4. The method of claim 1, further comprising rotating the optical fiber guide tube along its axis using a rotary drive mechanism to adjust the alignment of the optical fiber.

5. The method of claim 1, wherein the optical fiber core dimension matching ferrule tube is conFig.d to match the core dimensions of the optical fiber.

6. The method of claim 1, further comprising releasing the front and rear optical fiber clamp mechanisms after completing the lens grinding operation.

7. The method of claim 6, wherein releasing the front and rear optical fiber clamp mechanisms comprises:disengaging the locking mechanisms;deactivating the push-to-clamp holding mechanisms;deactivating the elastic clamp holding mechanisms.

8. The method of claim 1, wherein the lens grinding operation comprises forming a lens selected from the group consisting of: a conical lens, a wedge lens, a bionic lens, and a ball lens.

9. The method of claim 1, further comprising maintaining a lens placement accuracy of less than ±5 μm during the lens grinding operation.

10. The method of claim 1, wherein the optical fiber is a polarization-maintaining fiber, and further comprising aligning stress rods of the polarization-maintaining fiber with a tolerance of ±3 degrees.

11. The method of claim 1, further comprising processing multiple optical fibers in parallel using multiple sets of front and rear optical fiber clamp mechanisms.

12. An apparatus for clamping an optical fiber for lens grinding, comprising:a ferrule tube configured to match the core dimension of an optical fiber;a rotatable optical fiber guide tube for aligning the optical fiber;a front optical fiber clamp mechanism configured to secure a front portion of the optical fiber;a rear optical fiber clamp mechanism configured to secure a rear portion of the optical fiber; anda lens grinding mechanism configured to perform a lens grinding operation on an end of the optical fiber.

13. The apparatus of claim 12, wherein the front optical fiber clamp mechanism comprises:an elastic clamp holding mechanism;a push-to-clamp holding mechanism; anda locking mechanism.

14. The apparatus of claim 12, wherein the rear optical fiber clamp mechanism comprises:an elastic clamp holding mechanism;a push-to-clamp holding mechanism; anda locking mechanism.

15. The apparatus of claim 12, further comprising a rotary drive mechanism configured to rotate the optical fiber guide tube along its axis to adjust the alignment of the optical fiber.

16. The apparatus of claim 12, wherein the ferrule tube is configured to match the core dimensions of the optical fiber with a precision that ensures the fiber core remains centered and stable during the lens grinding operation.

17. The apparatus of claim 12, further comprising a release mechanism configured to disengage the front and rear optical fiber clamp mechanisms after completion of the lens grinding operation.

18. The apparatus of claim 12, wherein the lens is selected from the group consisting of: a conical lens, a wedge lens, a bionic lens, and a ball lens.

19. The apparatus of claim 12, further comprising multiple sets of front and rear optical fiber clamp mechanisms configured to process multiple optical fibers simultaneously in parallel.

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