Fan-Shaped Cladding Beam Combiner for High-Power Signal Transmission
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Solution Overview
Problem
Current methods for manufacturing signal beam combiners, such as knotting and sleeve methods, result in stress, fiber breakage, mode excitation, and poor light bearing capacity due to fusing and tapering processes, which also introduce air bubbles that attenuate optical signals.
Innovation Solution
A beam combiner for high-power signals is created using input and output optical fibers with fan-shaped or hexagonal cladding layers featuring grooves and protrusions, formed through laser etching, allowing nested fibers to connect without fusing or tapering, and a mechanical clamp for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fusing and tapering methods are used to manufacture beam combiners, then the optical fibers can be bound together to form a beam, but the fiber core is reduced and the quality of the combined beam deteriorates
Solution Approach 1:
The invention divides the binding process into two independent stages: first forming a loose bundle structure, then applying external force to compress and bind the fibers. This segmentation avoids the need for fusing that would damage the fiber core, maintaining manufacturing precision while achieving binding strength.
Solution Approach 2:
The invention introduces an intermediary binding structure (such as a metallic tube or polymer coating) that holds the optical fibers together without requiring direct fusing of the fiber cores. This intermediary medium provides the necessary binding strength while preserving the integrity and quality of the fiber cores.
2Ease of manufacture
If acid corrosion and tapering processes are used, then the optical fibers can be processed and bound, but the light bearing capacity of the beam combiner becomes weak
Solution Approach 1:
The invention extracts and removes the harmful acid corrosion and tapering processes from the manufacturing method. By using alternative binding techniques that do not require chemical etching or thermal tapering, the fiber core structure remains intact, preserving light bearing capacity while still enabling ease of manufacture through simplified processing steps.
Solution Approach 2:
The invention uses disposable or replaceable binding elements (such as metallic tubes or polymer coatings) that perform the binding function without permanently altering the optical fibers. These intermediary components can be applied easily and removed or replaced if needed, providing ease of manufacture without compromising the long-term reliability and light bearing capacity of the fibers.
3Strength
If fusing tapering processes are used, then the optical fibers can be bound into a beam, but air bubbles are generated in the inner cladding which cause signal attenuation
Solution Approach 1:
The invention performs preliminary actions to prevent bubble formation by using binding methods that do not involve high-temperature fusing processes. By establishing the bundle structure first and then applying gradual compression or binding forces, the process avoids conditions that would trap air bubbles in the cladding, thereby preventing signal attenuation while still achieving strong binding.
Solution Approach 2:
The invention replaces the thermal-mechanical fusing system with a purely mechanical binding system. By using external compression forces, metallic tubes, or polymer coatings to bind the fibers mechanically rather than through thermal fusing, the process eliminates the generation of air bubbles that would otherwise be trapped during high-temperature processing, thus preventing signal attenuation.
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 prevents fiber damage, eliminates signal attenuation from bubbles, enhances light bearing capacity, and improves heat dissipation, resulting in a robust and efficient transmission of high-power signals.
Implementation Method 1
The optical fiber input cladding layer is provided with the groove and/or the protrusion through etching by means of a laser
Implementation Method 2
the signal is transmitted in the input optical fiber through the total reflection
Data Source
AI summary
A beam combiner includes: a plurality of input optical fibers, a beam combination optical fiber and an output optical fiber; the input optical fiber includes an input fiber core and an optical fiber input cladding layer wrapping an outer wall of the input fiber core, the output optical fiber includes an output fiber core and an optical fiber output cladding layer wrapping an outer wall of the output fiber core, a cross section of the optical fiber input cladding layer is fan-shaped or hexagonal and is provided with a groove and/or a protrusion along an axial direction, the plurality of input optical fibers are nested with each other to form the beam combination optical fiber, fiber cores in the beam combination optical fiber are all connected to the output fiber core, and a beam combination cladding layer of the beam combination optical fiber is connected to the output fiber core.