Adhesive-Free Expanded Beam Fiber Array Unit for Precise Alignment
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Solution Overview
Problem
Existing fiber coupling methods using epoxies and glues for securing fibers to glass substrates and lenses in optical interconnects suffer from misalignment issues, are not reflow compatible, and degrade in vacuum environments due to outgassing.
Innovation Solution
Fusing glass fibers and lenses using a laser welding process to create a monolithic structure, eliminating the need for adhesives and enhancing alignment accuracy and reflow compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If epoxies and glues are used to secure fibers to V-grooves and lenses to fibers, then the fibers and lenses can be attached to the substrate, but the attachment process is not reflow compatible and leads to misalignment
Solution Approach 1:
The patent removes adhesives (epoxies and glues) from the optical coupling system entirely. Instead of using chemical adhesives to attach fibers to V-grooves and lenses to fibers, the invention uses a fusion process that directly bonds glass components through localized melting and bonding, eliminating the adhesive layer that causes misalignment and reflow incompatibility
Solution Approach 2:
The patent replaces the chemical bonding mechanism (adhesives) with a thermal/physical bonding mechanism (fusion). The fusion process uses localized heating to melt and bond glass surfaces directly, substituting the chemical adhesive system with a thermal field-based bonding system that achieves both strong attachment and high alignment precision
2Strength
If epoxies and glues are used to attach fibers and lenses, then the components can be secured, but the epoxies outgas in vacuum environments leading to degradation
Solution Approach 1:
The patent extracts and removes organic adhesives (epoxies and glues) from the system. By using a fusion process that bonds glass components through direct melting and bonding without any adhesive intermediaries, the invention eliminates the source of outgassing that would occur in vacuum environments, thereby improving reliability for space and vacuum applications
Solution Approach 2:
The patent changes the material composition parameter by using all-glass construction (fiber, V-groove substrate, and lens all made of glass materials with compatible melting points). This parameter change ensures that all components can withstand vacuum environments without outgassing, while the fusion process creates bonds as strong as or stronger than adhesive bonds
3Ease of manufacture
If manual lens attachment with optical glue is used, then lenses can be coupled to fibers, but the process is not well controlled leading to unacceptable misalignment
Solution Approach 1:
The patent replaces manual adhesive application with an automated fusion process. The fusion process uses controlled localized heating (such as laser heating or flame heating) to melt and bond the lens to the fiber tip, eliminating the need for manual glue application. This substitution provides precise control over the bonding process and alignment, achieving manufacturing precision unattainable with manual adhesive methods
Solution Approach 2:
The patent utilizes phase transition (melting and solidification) of glass materials to achieve bonding. By locally heating the glass lens and fiber tip to their melting point and then allowing controlled solidification, the process creates a strong, precise bond without requiring adhesive materials. The phase transition provides natural alignment through capillary action and surface tension effects during melting
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The fusion process reduces misalignment variability, improves reflow compatibility, and allows operation in vacuum environments by preventing outgassing, thereby enhancing optical coupling efficiency and system reliability.
Implementation Method 1
Fusing glass fibers and lenses using a laser welding process to create a monolithic structure
Data Source
AI summary
Embodiments disclosed herein comprise a substrate with a first surface and a second surface opposite from the first surface. In an embodiment, the substrate comprises a first glass material. In an embodiment, a lens is on the second surface of the substrate, and the lens comprises a second glass material. In an embodiment, a fiber is contacting the first surface of the substrate, and the fiber comprises a third glass material. In an embodiment, fiber is fused to the first surface of the substrate.