2D Fiber Array Structure with Spacer Layer for Position Tolerance
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Solution Overview
Problem
Conventional fiber arrays face challenges in achieving high-density, micron-level position accuracy and miniaturization due to limitations in machining processes, material constraints, and high production costs, leading to reduced yield and signal quality.
Innovation Solution
A two-dimensional fiber array structure with a baseboard and cover board featuring precision grooves and a spacer layer, allowing for accurate positioning of optical fibers with reduced position tolerance along the X-axis, enabling higher process yield and cost-effective mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If V-shaped grooves are machined one by one in glass substrates using cutting tools, then fibers can be positioned in the grooves, but the process time becomes long and the glass substrate is easy to break
Solution Approach 1:
The baseboard is divided into multiple layers with alternating grooves and flat surfaces. The grooves are pre-formed in the baseboard structure rather than machined individually, allowing parallel processing and reducing total process time while maintaining fiber positioning accuracy through the segmented groove design.
Solution Approach 2:
The grooves are pre-formed in the baseboard structure before fiber assembly. This preliminary action eliminates the need for time-consuming individual machining operations during the fiber assembly process, significantly reducing overall production time while maintaining precise fiber positioning through the pre-formed groove geometry.
2Manufacturing precision
If V-shaped grooves are machined one by one, then fibers can be positioned, but position tolerance accumulates and fiber position accuracy is reduced
Solution Approach 1:
Multiple groove formation operations are merged into a single baseboard structure with pre-formed grooves. This integration eliminates cumulative tolerances from sequential machining operations, as all grooves are formed simultaneously in the baseboard rather than individually, thereby reducing position tolerance accumulation and improving overall fiber position accuracy.
Solution Approach 2:
The groove pattern is replicated across multiple baseboard layers through a standardized design, allowing for consistent positioning tolerance control. The groove geometry is copied precisely across layers, ensuring uniform fiber positioning accuracy throughout the multi-layer structure without accumulating machining tolerances.
3Volume of moving object
If glass baseboard thickness is reduced below 0.3 mm, then miniaturization is achieved, but production difficulty increases and accuracy maintenance becomes hard
Solution Approach 1:
The baseboard structure uses composite construction with multiple layers of different materials or densities. This allows the overall structure to achieve miniaturization with reduced effective thickness while the composite nature provides structural strength and ease of manufacture, as each layer can be optimized for its specific function and manufactured using appropriate processes.
Solution Approach 2:
Instead of reducing baseboard thickness in a single dimension, the design distributes the structural function across multiple layers and dimensions. The groove structure extends into the thickness dimension, creating a three-dimensional positioning system that achieves miniaturization while maintaining manufacturability through the multi-dimensional distribution of structural and positioning functions.
4Quantity of substance
If multiple glass baseboards are stacked to form fiber array, then fiber density increases, but cost increases and accuracy maintenance becomes more difficult
Solution Approach 1:
Multiple baseboard layers are merged into an integrated structure where the groove patterns are pre-synchronized across all layers. This merging approach enables high fiber density through multi-layer stacking while maintaining accuracy by ensuring all layers share a common reference framework, thereby reducing the difficulty of accuracy maintenance and improving yield rate.
Solution Approach 2:
The baseboard layer structure serves multiple functions simultaneously: it provides mechanical support, defines groove positions, establishes alignment references, and enables fiber positioning. This multi-functionality reduces the need for separate components and processes in each layer, simplifying manufacturing and improving yield while achieving high fiber density.
Data Source
AI summary
The present disclosure relates to a two-dimensional fiber array structure including a base which includes a baseboard, a cover board and a spacer layer, and an optical fiber cable is positioned between the baseboard and the cover board, positioning fibers are positioned at two external sides of the optical fiber cable, the spacer layer is abutted with two adjacent fiber layers of the optical fiber cable to reduce the position tolerance along X axis for further improving accuracy, whereby ensuring quality and stability of transmitting optical signal.