Optical Fiber Alignment Device with Capillary Soldering
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Solution Overview
Problem
The challenge lies in accurately aligning and securely fastening the optical axis of an optical fiber with an opto-electronic component while minimizing the risk of misalignment due to thermal contraction and handling, which is exacerbated by the small dimensions of these components and the inaccuracy of existing methods.
Innovation Solution
A device featuring a framework with a bore for the optical fiber alignment, where solidifying fastening means migrate by capillarity action, ensuring symmetric contraction and maintaining the fiber's position, using melted soft solder or polymerizing glue for secure bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the optical fiber is fastened using solidifying fastening means (melted soft solder or polymerizing glue), then secure bonding is achieved, but asymmetric contraction forces during solidification cause misalignment and fiber movement
Solution Approach 1:
The patent applies asymmetry in reverse - it creates a symmetric configuration to eliminate asymmetric harmful effects. The optical fiber is positioned centrally within the bore, and the solidifying fastening means are distributed uniformly around the fiber, creating symmetric contraction forces that cancel each other out, preventing the asymmetric misalignment that would otherwise occur during solidification
Solution Approach 2:
The fastening process is segmented into two distinct phases: first, alignment is achieved and held fixed by the rigid framework structure; second, the solidifying fastening means are introduced and allowed to contract symmetrically. This segmentation allows the alignment function and fastening function to be performed independently, with the framework maintaining precision while the fastening material provides bonding strength
2Measurement precision
If the optical fiber is positioned with high precision for optimal coupling, then maximum signal transfer is achieved, but the position cannot be maintained during solidification due to unpredictable shrinkage forces
Solution Approach 1:
The rigid framework with precisely engineered bore provides beforehand cushioning for the optical fiber position. The framework's rigid structure compensates for the unpredictable shrinkage forces that will occur during solidification, maintaining the fiber's aligned position throughout the fastening process. The bore dimensions are specifically designed to accommodate the fiber while preventing lateral movement
Solution Approach 2:
The framework acts as an intermediary between the optical fiber and the solidifying fastening means. It provides a stable, rigid structure that maintains alignment while allowing the fastening material to solidify around the fiber. The framework mediates the conflicting requirements of precise positioning and robust fastening
3Ease of operation
If the optical fiber is moved with a micromanipulator for dynamic alignment, then optimal coupling is achieved, but the delicate operation requires extreme accuracy on the order of or less than 1 μm in all three axes
Solution Approach 1:
The framework with its precisely manufactured bore provides preliminary action by pre-establishing the alignment geometry. The bore is designed with specific dimensions and tolerances that guide the optical fiber into the correct position, eliminating the need for complex micromanipulator operations. The rigid structure performs the alignment function beforehand, simplifying the overall process
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 alignment and secure fastening of the optical fiber, maintaining optimal coupling and stability over time despite temperature and humidity changes, and reduces the risk of fiber breakage during solidification.
Implementation Method 1
the solidifying fastening means migrate from the tank to the bore by capillarity action
Implementation Method 2
when the solidifying fastening means are solidified around the optical fiber
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
An embodiment of the invention relates to a device (1) for aligning the optical axis (2) of an optical fiber (3) with the optical axis (4) of an opto-electronic component (5) and for fastening the optical fiber (3) in the resulting relative position in relation to the opto-electronic component (5), said device (1) comprising an opto-electronic component (5) comprising an optical axis (4), a base (6) construed and arranged to support a framework, and a first framework (7) disposed onto said base (6). The first framework (7) comprises : - a bore (9) having a longitudinal axis (10) sensibly coaxial to the optical axis (4) of the opto-electronic component (5), said bore (9) being construed and arranged to receive an optical fiber (3), - a tank (11) construed and arranged to contain solidifiable fastening means (12), and - a duct (13) connected at a first end to said tank (11) and at a second end to said bore (9) so that solidifiable fastening means (12) are capable to migrate from the tank (11) to the bore (9) by capillarity action.