Fiber Array Spacers Using Precision-Diameter Optical Fibers
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Solution Overview
Problem
The challenge lies in fabricating optical fiber array spacers with precise thickness, as traditional methods for creating substrates with uniform thickness are costly and time-consuming, and existing solutions do not efficiently address the need for precise vertical pitch and lateral pitch in fiber array assemblies.
Innovation Solution
The use of precision-diameter optical fibers to create fiber array spacers, where the fibers are interdigitated and bonded using UV-curable adhesives and laser bonding, allowing for precise alignment and thickness control, enabling low-cost fabrication of two-dimensional fiber arrays and other optical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If substrates of precise thickness are used to provide precise height tolerances, then manufacturing precision is improved, but cost increases and fabrication difficulty worsens
Solution Approach 1:
The patent uses standard thickness substrates instead of expensive precision-thickness substrates. The fiber array spacer with precise height is constructed by bonding fibers vertically onto the substrate surface, making the substrate itself disposable or standard-grade while achieving precision through the fiber spacer structure.
Solution Approach 2:
The height precision function is segmented from the substrate to the fiber array spacer structure. The substrate provides only mechanical support, while the vertically bonded fibers create the precise height tolerance through their controlled length and uniform diameter, separating the precision requirement from the substrate fabrication process.
2Manufacturing precision
If substrates are machined or etched to desired thickness, then manufacturing precision is improved, but time consumption and cost increase
Solution Approach 1:
The precise height is established in advance by selecting fibers of specific lengths and bonding them vertically to the substrate before final assembly. This preliminary positioning of fibers at precise heights eliminates the need for time-consuming post-substrate machining or etching operations to achieve the desired thickness precision.
Solution Approach 2:
The patent replaces mechanical machining or etching processes with a chemical bonding process. UV-curable adhesive is applied to bond fiber ends to the substrate surface, and the cured adhesive creates precise spacing without requiring subtractive manufacturing operations on the substrate itself.
3Strength
If traditional substrate methods are used for fiber array assembly, then structural support is provided, but alignment precision and debris immunity worsen
Solution Approach 1:
The fiber array spacer acts as an intermediary element between the substrate and the opposing fiber array or optical component. The spacer fibers provide both mechanical support and precise alignment, while the UV-curable adhesive serves as an intermediary bonding agent that cures to create a stable, debris-immune interface.
Solution Approach 2:
The fiber array spacer creates a composite structure combining the substrate material with the fiber material and UV-curable adhesive. This composite construction provides both structural strength from the substrate and fibers, while the cured adhesive joints create precise, stable alignment interfaces that are resistant to debris accumulation.
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 method allows for the cost-effective production of optical components with precise vertical alignment, reducing fabrication time and errors, and providing a stable, debris-immune surface for optical assemblies.
Implementation Method 1
bonded using UV-curable adhesives
Implementation Method 2
laser bonding
Data Source
Figure 1A~1C
Figure 2A~2B
Figure 3A~3B
AI summary
Fiber array spacers, optical fiber assemblies, optical assemblies, and methods for fabricating optical assemblies are disclosed. In one embodiment, an optical fiber assembly includes a fiber array spacer and a fiber ribbon having an array of optical fibers. The fiber array spacer has an array of spacer fibers, wherein individual spacer fibers of the array of spacer fibers are bonded to one another, and a diameter of the individual spacer fibers determines a height of the fiber array spacer. Each optical fiber of the array of optical fibers has an glass portion. The glass portion of each optical fiber is bonded to the fiber array spacer such that a longitudinal axis of the individual spacer fibers is transverse to a longitudinal axis of individual optical fibers of the fiber ribbon.