Fiber Array Adapter V-Grooves for Pin-Free Optical Alignment
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Solution Overview
Problem
Existing methods for aligning optical fibers with integrated waveguides are time and resource intensive, and incorporating alignment pins in waveguide substrates limits design flexibility and introduces thermal stress issues.
Innovation Solution
The use of high-contrast V-grooves formed in a glass substrate with a non-transparent layer, allowing precise alignment through machine vision techniques, eliminating the need for alignment pins directly in waveguide substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If alignment pins are incorporated in waveguide substrates, then alignment precision is improved, but device complexity and thermal stress increase
Solution Approach 1:
The patent removes alignment pins from the waveguide substrate and replaces them with V-grooves that directly receive and position the optical fibers. This extraction eliminates the need for separate alignment pin components and their associated mounting structures, thereby reducing device complexity while maintaining alignment precision through the V-groove geometry itself.
Solution Approach 2:
The V-grooves serve as an intermediary structure between the waveguide substrate and the optical fibers. Instead of using alignment pins that require precise mounting, the V-grooves provide a self-aligning mechanical interface that guides fiber placement, eliminating thermal stress issues associated with pinned connections while preserving alignment accuracy.
2Manufacturing precision
If alignment pins are used for precise alignment, then manufacturing precision is improved, but thermal stress issues arise
Solution Approach 1:
By removing alignment pins from the system and replacing them with V-groove structures, the patent eliminates the source of thermal stress. The V-grooves provide a passive mechanical guidance structure that does not require thermal expansion-matched materials or stress-free mounting conditions, thereby eliminating thermal stress issues while maintaining alignment precision.
3Manufacturing precision
If traditional alignment methods are used, then alignment precision can be achieved, but assembly time and cost increase
Solution Approach 1:
The V-grooves are pre-formed in the waveguide substrate with precise geometry and positioning before fiber assembly. This preliminary action creates self-aligning features that guide the optical fibers into correct positions during assembly, eliminating the need for time-consuming active alignment procedures and thereby increasing assembly speed while maintaining precision.
Solution Approach 2:
The V-groove structure provides self-aligning functionality, where the geometry of the grooves automatically guides the optical fibers into the correct positions during assembly. This self-service alignment mechanism eliminates the need for external alignment tools, adjustment mechanisms, or complex positioning procedures, thereby significantly increasing assembly speed while maintaining alignment precision.
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3B
AI summary
An FAU adapter includes a glass substrate and a non-transparent layer coated on the first surface of the glass substrate. The glass substrate includes a first surface that is parallel with both a fiber direction of the FAU adapter and an alignment direction of the FAU adapter, wherein the alignment direction is orthogonal to the fiber direction. A plurality of V-grooves are formed within the glass substrate and the non-transparent layer, each V-groove of the plurality of V-grooves including a V-groove axis that extends in the fiber direction, and each V-groove of the plurality of V-grooves extending through the non-transparent layer and through the first surface of the glass substrate.