Centering Ferrule Mount for Polymer Waveguide Alignment
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Solution Overview
Problem
Existing technologies face challenges in achieving precise alignment and reliable optical connections between polymer waveguides on printed circuit boards and optical elements without the need for additional alignment equipment.
Innovation Solution
A centering ferrule mount with tapered features forms an interference fit with the polymer waveguide, allowing for simple sliding engagement and alignment, which is then bonded to the circuit board using a quick-curing adhesive, optionally secured with fixation screws.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional mechanical alignment methods are used to align polymer waveguides with optical elements, then alignment precision can be improved, but device complexity and the need for additional alignment equipment increase
Solution Approach 1:
The polymer waveguide structure includes built-in reference waveguide cores that serve as self-alignment features. The ferrule mount aligns to these reference cores through interference fit, enabling the waveguide to align itself with optical elements without external alignment equipment. The reference cores effectively make the waveguide self-aligning, eliminating the need for separate alignment tools or mechanisms.
Solution Approach 2:
The reference waveguide cores are pre-formed as integral parts of the polymer waveguide structure during manufacturing. These reference features are created beforehand to establish precise geometric relationships, allowing the ferrule mount to achieve accurate alignment simply by mating with these pre-positioned reference cores, rather than requiring alignment adjustments during assembly.
2Reliability
If interference fit is used to secure the ferrule mount to the polymer waveguide, then connection reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The reference waveguide cores are designed with specific dimensional parameters (larger cross-sectional dimensions than data-carrying cores) to create an interference fit condition. By changing the size parameters of the reference cores, the design ensures that when the ferrule mount's tapered features are pressed against them, elastic deformation occurs, generating sufficient frictional force for reliable mechanical attachment without requiring ultra-precise manufacturing tolerances.
Solution Approach 2:
The ferrule mount incorporates tapered features with curved surfaces that mate with the reference waveguide cores. This curved/tapered geometry allows for gradual engagement and distributes contact stresses, facilitating the interference fit mechanism while accommodating reasonable manufacturing variations. The tapered shape enables smooth insertion and secure locking through elastic deformation of the reference cores.
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
This solution ensures precise and reliable optical connections between polymer waveguides and optical elements, eliminating the need for extra alignment tools and providing a secure attachment.
Implementation Method 1
The interference fit provides alignment of the centering ferrule mount and ensures a reliable optical connection
Data Source
AI summary
An apparatus includes a polymer waveguide element disposed on a circuit board and having a waveguide core between a first outer reference waveguide core and a second reference waveguide core having top and side exposed surfaces and defining opposing outer edges of the polymer waveguide element. A ferrule mount element optically couples the polymer waveguide element to an optical element through the circuit board. The ferrule mount includes two tapered features that mate with and form an interference fit with the exposed side surfaces of the first outer reference waveguide core and second outer reference waveguide core.