Curable Filler Fiber Array Assembly for Alignment Stability
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Solution Overview
Problem
Existing fiber array technologies face challenges in maintaining alignment and assembly complexity due to multiple hardware components, which lead to movement and misalignment of optical fibers, especially when bending them between 60 degrees and 120 degrees, resulting in signal loss and increased assembly difficulty.
Innovation Solution
A single-piece fiber array design with a recessed base and a curable filler material that secures optical fibers within V-grooves, eliminating the need for multiple hardware components and ensuring alignment by fixing the fibers in place once the filler cures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple hardware components are used to secure optical fibers, then the fibers can be held in place, but the assembly complexity increases and the fibers become susceptible to movement and misalignment
Solution Approach 1:
The patent combines multiple separate components (base, guide, lids, clips) into a single integrated component with built-in V-grooves and fiber retention features. This merging eliminates the need for multiple discrete parts while maintaining fiber alignment and security, directly resolving the contradiction between reliability and device complexity.
Solution Approach 2:
The single component performs multiple functions: it provides the base structure, contains V-grooves for fiber alignment, includes guides for positioning, and has integrated retention features. This multi-functionality replaces what previously required multiple specialized components, reducing assembly complexity while maintaining fiber security.
2Ease of manufacture
If a tight mechanical fit is used to secure components, then assembly is simpler, but manufacturing tolerances must be extremely tight increasing cost
Solution Approach 1:
The patent changes the physical state of the filler material from liquid to solid through curing, transforming it from a flowable substance that fills gaps to a rigid structural element. This parameter change allows the use of less precise mechanical fits while maintaining secure fiber retention, as the cured filler compensates for tolerance variations.
Solution Approach 2:
The filler material acts as an intermediary substance between the mechanical components and optical fibers. It fills gaps and secures fibers without requiring precise mechanical interference fits, mediating between the imperfect mechanical fit and the need for secure fiber retention.
3Ease of operation
If mechanical components are used to secure fiber bundles, then assembly is straightforward, but the components move due to heat expansion causing misalignment
Solution Approach 1:
The patent utilizes the curing process parameter change of the filler material to transform it from a flexible, flowable state during assembly to a rigid, stable state after curing. This allows easy assembly in the liquid state while achieving stable, heat-resistant fixation in the cured state, preventing thermal expansion-induced misalignment.
4Device complexity
If a single-piece design is used, then assembly is simplified, but the fibers may not be securely held without additional filling material
Solution Approach 1:
The filler material serves as an intermediary that bridges the gap between the simplified single-piece design and the need for secure fiber retention. It provides the necessary holding force and alignment stability without requiring complex mechanical features, allowing the base itself to be simple while the filler ensures fiber security.
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 simplifies the assembly process, maintains fiber alignment, and enhances environmental durability by preventing movement of the optical fibers, thereby reducing signal loss and improving the overall reliability of the fiber array.
Implementation Method 1
a curable filler material that secures optical fibers within V-grooves, eliminating the need for multiple hardware components and ensuring alignment by fixing the fibers in place once the filler cures
Data Source
AI summary
A fiber array device configured to secure and align one or more optical fiber bundles as part of a main body using a fixing material. The fixing material is light cured or room temperature cured. Main body forms an angle from a first direction along a second direction, and a recess the optical bundles are laid within and in which the fixing material is applied. Each individual optical fiber is laid within a groove formed in a lid, the base portion or both the lid and the base portion. The fiber array device is secured to a printed circuit board to form a communication path between the optical fiber and electronics of the board.