Ferrule-less Optical Fiber Alignment Device Using Molded Groove
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Solution Overview
Problem
Existing optical fiber alignment methods, particularly those using ferrules, face challenges in achieving precise alignment while being costly and complex, and there is a need for more cost-effective ferrule-less solutions that can accurately align optical fibers for efficient optical coupling.
Innovation Solution
A ferrule-less optical fiber alignment device using a molded plastic housing with tapered funnels and an alignment groove, combined with biasing mechanisms like springs and balls, to coaxially align optical fibers, potentially utilizing index matching gel to reduce Fresnel reflections and enhance optical coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ferrule-based alignment systems are used, then fiber alignment precision is improved, but manufacturing cost and device complexity increase significantly
Solution Approach 1:
The patent extracts and removes the ferrule component from the alignment system, replacing it with a ferrule-less design that uses a alignment groove and positioning structures directly integrated into the connector body. This eliminates the need for separate ferrules while maintaining alignment precision through alternative mechanical guidance features.
Solution Approach 2:
The alignment functionality previously provided by separate ferrules is merged directly into the connector body through integrated alignment grooves and positioning structures. This consolidation reduces the number of components and simplifies the overall device while achieving the same alignment function.
2Manufacturing precision
If ferrule-based alignment systems are used, then fiber alignment precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive ceramic or metal ferrules with a more economical plastic or polymer-based alignment structure that is molded directly into the connector. This substitution uses cheaper materials and manufacturing processes while achieving sufficient alignment precision for the application.
Solution Approach 2:
The invention changes the material parameters from traditional ceramic/metal ferrules to plastic or polymer materials, and changes the manufacturing method from precision drilling and assembly to molded integration. These parameter changes reduce manufacturing cost while maintaining functional performance.
3Reliability
If index matching gel is applied, then optical coupling efficiency is improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The alignment groove structure is designed to automatically position and retain the index matching gel in the optimal location between fiber ends during the connection process. The groove acts as a self-contained feature that guides the gel into place without requiring additional application steps or complex dispensing mechanisms.
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 solution provides accurate and cost-effective end-to-end alignment of optical fibers, reducing manufacturing costs and improving optical coupling efficiency by minimizing Fresnel reflections, thus facilitating reliable optical connections.
Implementation Method 1
utilizing index matching gel to reduce Fresnel reflections and enhance optical coupling
Implementation Method 2
Optical fibers are strands of glass fiber processed so that light beams transmitted through the glass fiber are subject to total internal reflection
Data Source
AI summary
The present disclosure relates to an optical fiber alignment device that has an alignment housing that includes first and second ends. The alignment housing defines a fiber insertion axis that extends through the alignment housing between the first and second ends. The alignment housing includes a fiber alignment region at an intermediate location between the first and second ends. First and second fiber alignment rods are positioned within the alignment housing. The first and second fiber alignment rods cooperate to define a fiber alignment groove that extends along the fiber insertion axis. The first and second fiber alignment rods each having rounded ends positioned at the first and second ends of the alignment housing.