Optical Fiber Assembly Pitch Conversion via Gripper Stretching
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Solution Overview
Problem
The existing methods for manufacturing optical fiber assemblies with small-diameter optical fibers are cumbersome and time-consuming due to the mismatch between the fiber coatings and the pitch of existing MT ferrules, requiring individual insertion and alignment of fibers.
Innovation Solution
A method using an alignment member with through holes arranged at a pitch greater than the fiber coating diameter, where optical fibers are inserted, held by grippers, and bonded with an adhesive material cured while stretched, ensuring alignment and integration with a predetermined pitch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If optical fibers with small coating diameter (e.g., 160 μm) are used to reduce fiber ribbon size, then the size of fiber assembly is reduced, but the fibers cannot be aligned with existing MT ferrule pitch (e.g., 250 μm) requiring individual insertion
Solution Approach 1:
A pitch conversion member is introduced as an intermediary component between the optical fibers and the MT ferrule. This member has through-holes arranged at a pitch matching the MT ferrule (e.g., 250 μm), which is larger than the fiber coating diameter (e.g., 160 μm). The optical fibers are inserted through these through-holes, allowing them to be positioned at the correct pitch without requiring individual manual alignment with the ferrule insertion holes.
Solution Approach 2:
The alignment and integration process is divided into distinct functional segments: the pitch conversion member handles the pitch transformation function, the grippers handle the stretching and positioning function, and the adhesive material handles the bonding function. This segmentation allows each component to be optimized for its specific function and simplifies the overall manufacturing process.
2Manufacturing precision
If adhesive material is applied to bond optical fibers without stretching, then the curing process may cause pitch variation, but stretching during curing requires precise positioning
Solution Approach 1:
The optical fibers are pre-positioned and stretched to the correct pitch between the grippers before the adhesive material is applied and cured. This preliminary stretching action ensures that the fibers are at the correct pitch while the adhesive sets, preventing pitch variation during curing. The pitch conversion member's through-holes guide the fibers into the correct positions before stretching.
Solution Approach 2:
The physical state of the adhesive material is utilized during the curing process. The adhesive is applied in a liquid or semi-liquid state that allows the fibers to be stretched and repositioned, then cured to lock the fibers in their stretched, correctly-positioned state. This parameter change (from liquid to solid) enables both flexibility during positioning and rigidity in the final product.
3Adaptability or versatility
If multiple optical fibers are inserted into MT ferrule one by one to maintain compatibility, then compatibility is maintained, but the process becomes very time-consuming
Solution Approach 1:
Multiple optical fibers are pre-assembled into a bundle with correct pitch using the pitch conversion member and grippers, before being inserted into the MT ferrule as a unit. This preliminary assembly action transforms the process from inserting one fiber at a time to inserting a pre-aligned bundle, dramatically increasing productivity while maintaining compatibility with existing MT connectors.
Solution Approach 2:
The pitch conversion member acts as a mediator that enables batch processing of multiple fibers. By providing through-holes at the correct pitch, it allows multiple fibers to be positioned and stretched simultaneously, then transferred as a group to the MT ferrule, maintaining compatibility while improving manufacturing efficiency.
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 and rapid integration of multiple optical fibers with a predetermined pitch, preventing pitch variation during curing and enabling easy alignment over a wide range, thus simplifying the manufacturing process.
Implementation Method 1
an adhesive material is formed on at least one side of the alignment member such that at least adjacent optical fibers of the plurality of optical fibers are connected to each other
Data Source
AI summary
A method of manufacturing an optical fiber assembly into which optical fibers are integrated includes: preparing an alignment member having through holes with a pitch that is greater than a coating diameter of the optical fibers; inserting each of the optical fibers into one of the through holes; after the inserting of the optical fibers into the through holes, holding the optical fibers on both sides of the alignment member by a pair of grippers; after the inserting of the optical fibers into the through holes, connecting at least adjacent ones of the optical fibers by disposing an adhesive material on at least one side of the alignment member; and forming an optical fiber assembly by curing the adhesive material in a state in which the optical fibers held by the grippers are stretched along an optical axis.