High-Density Fiber Array Unit With Stacked Substrates
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Solution Overview
Problem
Conventional fiber array units have limitations in accommodating a high number of optical fibers, leading to constraints in data throughput and space efficiency.
Innovation Solution
The fiber array apparatus includes a fiber array unit mounted on a packaging plate with a protective cover and a spacing plate, utilizing substrates with positioning grooves for fiber alignment and adhesives for secure fixation, allowing for a higher density of fibers, such as 400 fibers in a single unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional fiber array units with substrate and cover plate are used, then structural simplicity is maintained, but the number of fibers that can be accommodated is limited to 2-64 fibers
Solution Approach 1:
The fiber array unit is divided into multiple substrates, with each substrate accommodating a specific number of fibers (e.g., 20 fibers per substrate). This segmentation allows the system to scale from 2-64 fibers in conventional units to 400 fibers by simply adding more substrate modules, thereby increasing fiber quantity while maintaining manageable structural complexity through modular design.
Solution Approach 2:
Multiple substrates are stacked and nested within a single fiber array unit, with each substrate containing an array of positioning holes for fibers. The substrates are arranged in layers (e.g., 10 substrates × 20 fibers per substrate = 200 fibers, or 20 substrates × 20 fibers = 400 fibers), enabling high-density fiber accommodation while maintaining a compact overall structure.
2Productivity
If the number of fibers is increased to 400 in a single unit, then data throughput is improved, but space efficiency becomes constrained
Solution Approach 1:
Instead of arranging 400 fibers in a single plane (which would require large area), the invention stacks multiple substrates in the vertical dimension (z-axis). Each substrate layer contains a manageable array of fibers (e.g., 20 fibers), and multiple layers (e.g., 10 or 20 layers) are stacked to achieve 400 total fibers. This three-dimensional arrangement dramatically reduces the horizontal footprint while accommodating high fiber density, thus improving space efficiency while maintaining high data throughput capability.
3Quantity of substance
If multiple substrates are stacked to increase fiber density, then fiber accommodation capacity is improved, but alignment precision becomes more difficult to maintain
Solution Approach 1:
Positioning holes are pre-formed in each substrate at precise locations before fiber insertion. The substrates are designed with predetermined hole patterns that ensure correct fiber positioning. This preliminary preparation of positioning structures eliminates the need for complex real-time alignment during assembly, maintaining high manufacturing precision even when stacking multiple substrates to achieve high fiber density.
Solution Approach 2:
The substrates themselves act as intermediary structures that provide mechanical support and precise positioning for the fibers. Each substrate includes an array of positioning holes that serve as intermediaries to hold fibers in exact positions. When multiple substrates are stacked, these intermediary positioning structures ensure that fibers in different layers remain precisely aligned, maintaining alignment precision while enabling high fiber density through multi-layer stacking.
Data Source
AI summary
A high-density fiber array unit includes a plurality of substrates arranged and connected in an array, a side plate arranged at one side of the plurality of substrates and connected to one of the plurality of substrates, and a plurality of fibers. Each substrate comprises a first surface and a second surface opposing the first surface, and the first surface defines positioning grooves. The side plate is connected to the first surface of one of the substrates, and each fiber can be fixed to and held by a positioning groove. A fiber array apparatus including the fiber array unit is also provided.