Optical Fiber Array Substrate Groove Design for Epoxy Control
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Solution Overview
Problem
Traditional substrates for optical fiber arrays face issues such as hard epoxy spreading and causing cracks in optical fiber coatings, insufficient binding strength leading to breakage under bending forces, and inconsistent fiber placement due to lack of positioning datum.
Innovation Solution
A substrate design featuring a main body with notched first and arc-shaped second holding grooves for stripped and unstripped optical fibers respectively, a lid to cover the stripped fiber, and a groove to prevent epoxy overflow, ensuring uniform alignment and strong fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hard epoxy is used to fix optical fibers, then the binding strength is improved, but the epoxy spreads to the rear of the substrate and causes cracks in the optical fiber coating
Solution Approach 1:
The substrate is divided into distinct functional zones: a first holding groove for stripped optical fibers with strong epoxy bonding, and a second holding groove for unstripped optical fibers with a softer epoxy layer. This segmentation allows different epoxy properties in different regions, preventing harmful spread while maintaining necessary binding strength.
Solution Approach 2:
Different regions of the substrate have different epoxy characteristics - the first holding groove uses hard epoxy for strong fixation, while the second holding groove uses soft epoxy to accommodate unstripped fibers without causing cracks. This local differentiation resolves the contradiction between binding strength and harmful spread.
2Ease of manufacture
If the substrate structure is simplified, then the manufacturing process is easier, but the placement consistency of stripped optical fibers deteriorates
Solution Approach 1:
The substrate pre-provides a second holding groove with soft epoxy that temporarily holds unstripped optical fibers in precise positions before stripping. This preliminary positioning action ensures that after stripping, the fibers maintain consistent placement in the first holding groove, achieving manufacturing precision without complex processes.
Solution Approach 2:
The second holding groove with soft epoxy acts as an intermediary that temporarily holds unstripped fibers in correct positions. This intermediary structure transfers the positioning function from a complex datum system to a simple groove structure, maintaining precision while simplifying manufacturing.
3Strength
If the epoxy binding strength at the rear of the substrate is increased, then the optical fiber fixation is improved, but the optical fiber breaks under bending forces
Solution Approach 1:
The substrate applies different epoxy hardness levels to different locations: hard epoxy in the first holding groove for strong fixation of stripped fibers, and soft epoxy in the second holding groove for gentle holding of unstripped fibers. This local differentiation provides both strong fixation and fiber integrity under bending.
Solution Approach 2:
The epoxy hardness parameter is changed based on location and fiber state. Soft epoxy is used where unstripped fibers are held to prevent breakage, while hard epoxy is used where stripped fibers require strong fixation. This parameter differentiation resolves the contradiction between fixation strength and fiber integrity.
Data Source
AI summary
Some embodiments of the disclosure provides a substrate for optical fiber array and the disclosed substrate fixes the fiber by epoxy. In some embodiments, the substrate includes a main body, a first holding groove, and a second holding groove. The first holding groove is notched along a width direction of the main body for holding a stripped optical fiber by epoxy. The second holding groove is an arc-shaped groove and connected with the first holding groove. The second holding groove extends along a notching direction of the first holding groove for holding an unstripped optical fiber. In other embodiments, a groove is notched along a length direction of the main body to prevent epoxy overflow.