Optical Fiber Assembly Coplanarity via Laser Cleaving
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Solution Overview
Problem
Laser cleaved optical fibers often have end faces that do not lie in a common plane, making it difficult to position them accurately for mating, especially in multi-fiber cables, where movement of one fiber can affect adjacent fibers, and require costly mechanical polishing for smoothness.
Innovation Solution
An optical fiber assembly with a ferrule and bores that allows laser cleaving of optical fibers to create end faces which are then moved and fixed to ensure coplanarity, eliminating the need for mechanical polishing and using enlarged portions to secure fibers in place, with optional active alignment for precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If laser cleaving is used to cut optical fibers, then the end faces are smooth without requiring polishing, but the end faces do not lie in a common plane and vary in length by 15 μm or more
Solution Approach 1:
The patent changes the physical state of the optical fiber end portion by creating an enlarged portion through laser cleaving parameters. This enlarged portion serves as a positioning feature that engages with the ferrule to ensure coplanarity of the end faces, while maintaining the smooth surface quality achieved by laser cleaving without requiring subsequent polishing operations.
Solution Approach 2:
The enlarged portion acts as an intermediary element between the optical fiber and the ferrule. It provides a mechanical engagement feature that mediates the positioning of the fiber end face relative to the ferrule front face, ensuring coplanarity without requiring the entire fiber to be mechanically polished.
2Ease of manufacture
If mechanical cleaving is used to cut optical fibers, then the process is simple, but the end faces are rough and require costly mechanical polishing to achieve sufficient smoothness
Solution Approach 1:
The patent replaces the mechanical polishing process with a laser-based solution. The laser cleaving process creates both the smooth end face and the enlarged positioning portion in a single operation, eliminating the need for subsequent mechanical polishing steps while maintaining both surface quality and dimensional precision.
3Manufacturing precision
If optical fibers are moved independently to position end faces in a common plane, then coplanarity can be achieved, but movement of one fiber causes movement of adjacent fibers in multi-fiber cables
Solution Approach 1:
The patent segments the optical fiber into distinct functional portions: the end face portion for light transmission and the enlarged portion for positioning. This segmentation allows the enlarged portion to engage with the ferrule and provide independent positioning control for each fiber, enabling coplanarity adjustment without affecting adjacent fibers in multi-fiber cables.
Solution Approach 2:
The patent introduces a dimensional feature (the enlarged portion) that extends beyond the standard fiber diameter. This additional dimension provides a mechanical engagement interface with the ferrule that enables precise positioning of the fiber end face in the axial direction, achieving coplanarity through a different dimensional approach rather than attempting to move entire fibers.
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 efficient assembly of optical fibers with smooth, coplanar end faces without polishing, reducing costs and improving alignment accuracy, enabling reliable light transmission while accommodating variations in fiber length caused by laser cleaving.
Implementation Method 1
Laser cleaving may cleave or cut the optical fibers and produce end faces on the optical fibers that do not require polishing.
Data Source
AI summary
An optical fiber assembly includes a ferrule and a plurality of optical fibers. Each optical fiber has an end portion positioned generally adjacent a front face of the ferrule. The end portion of each optical fiber has an end face for engaging a mating optical component and an enlarged portion with at least a portion thereof engaging the ferrule generally adjacent the front face of the ferrule. A method of fabricating an optical fiber assembly is also disclosed.