Optical Fiber Bundle Ferrule Segmentation for Alignment
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Solution Overview
Problem
In optical fiber bundles, the insertion of multiple optical fibers into a ferrule can lead to positional deviations, resulting in excessive curvature and increased bending loss due to improper alignment and diameter mismatch, which complicates optical coupling and measurement processes.
Innovation Solution
The optical fiber bundle design includes a ferrule with a unique inner diameter transition portion and a coating arrangement where the first diameter portion, tapered portion, and second diameter portion of each optical fiber are strategically inserted and fixed, ensuring proper alignment and reducing curvature by integrating the coating portions to prevent excessive insertion and crossing of fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple optical fibers are inserted into a ferrule, then the fiber bundle can be formed, but positional deviations occur resulting in excessive curvature and increased bending loss
Solution Approach 1:
The ferrule's fiber accommodating hole is divided into multiple sections with different inner diameters (first portion with smaller diameter, second portion with larger diameter, and transition portion). This segmentation allows different portions of each optical fiber to be accommodated in different sections, enabling precise control of fiber curvature and reduction of bending loss while maintaining proper alignment for optical coupling.
Solution Approach 2:
Different sections of the fiber accommodating hole are designed with locally optimized inner diameters. The first portion has a smaller inner diameter to constrain and align the fiber tip, while the second portion has a larger inner diameter to reduce curvature. This local quality variation throughout the ferrule structure systematically controls fiber positioning and minimizes bending loss.
2Manufacturing precision
If optical fibers are inserted to achieve proper alignment, then optical coupling is improved, but excessive insertion causes excessive curvature and bending loss
Solution Approach 1:
The fiber accommodating hole is segmented into a first portion with smaller inner diameter for precise alignment and a second portion with larger inner diameter for curvature reduction. This segmentation enables the system to achieve both proper alignment and reduced bending loss simultaneously by distributing the fiber through different sections with different geometric constraints.
Solution Approach 2:
The problem is solved by adding a dimensional variation in the ferrule structure - transitioning from a uniform diameter hole to a variable diameter hole with a transition portion. This dimensional change in the ferrule's inner diameter profile provides an additional degree of freedom to control fiber curvature and alignment independently.
3Productivity
If optical fibers are inserted into the ferrule, then the fiber bundle is formed, but fiber crossing and improper alignment occur
Solution Approach 1:
The ferrule's fiber accommodating hole is divided into multiple sections with different inner diameters. The first portion with smaller diameter provides a constraining zone for alignment, while the second portion with larger diameter allows fiber passage with reduced curvature. This segmentation creates a systematic guide that prevents fiber crossing and maintains proper alignment during bundle formation.
Solution Approach 2:
The ferrule structure is designed in advance with the variable inner diameter profile, creating a pre-established guidance path for the optical fibers. This preliminary structural arrangement ensures that fibers are automatically positioned correctly as they are inserted, preventing crossing and misalignment without requiring additional alignment operations.
Data Source
AI summary
An optical fiber bundle includes a ferrule, a holding portion, and a plurality of optical fibers. The holding portion has a fiber accommodating hole. The plurality of optical fibers each have a glass fiber and a coating portion. The glass fiber has a first diameter portion and a second diameter portion. The coating portion is formed by covering a glass fiber continuous with the second diameter portion with a coating. The coating portion includes a first portion led out from the fiber accommodating hole. The coating of the first portion of each of the plurality of optical fibers is fixed to the coating of the first portion of at least one optical fiber among the other optical fibers. An arrangement order of the coating portions in the fiber accommodating hole is the same as an arrangement order of the plurality of optical fibers at the front end of the ferrule.