Push-Pull Fiber Connector Clocking for Multi-Core Laser Alignment
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Solution Overview
Problem
Existing systems face challenges in aligning multi-core fibers with multi-spot laser beam patterns, leading to decreased coupling efficiency and power uniformity due to misalignment, which can affect the transmission of laser spots into the fiber cores and increase unwanted transmission outside the cores.
Innovation Solution
A system comprising a port adapter with a cylindrical barrel, a tapered surface, a clocking key, and a tapered cam slot, along with a sleeve for high precision lateral alignment, facilitates quasi-helical guided rotation and friction-resistant insertion of optical fibers, ensuring alignment within approximately 10 microns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional alignment methods are used, then the alignment process is simple, but the alignment precision deteriorates leading to misalignment between fiber cores and laser spots
Solution Approach 1:
The patent applies preliminary action by pre-configuring the tapered cam slot and clocking key geometry before insertion. The tapered cam slot is precisely machined at specific angles (e.g., 15-30 degrees) and the clocking key is pre-positioned on the connector body. This pre-prepared geometric configuration enables automatic alignment during the insertion process itself, achieving high precision (within 10 microns) without requiring complex external alignment equipment or manual adjustment procedures.
Solution Approach 2:
The patent introduces the tapered cam slot as an intermediary element between the connector and adapter. This intermediate geometric feature mediates the alignment process by converting simple insertion motion into precise rotational and lateral positioning. The cam slot acts as a mechanical intermediary that translates linear insertion force into the complex quasi-helical motion required for high-precision fiber-to-laser alignment, thereby achieving high precision without directly complexifying the overall alignment mechanism.
2Productivity
If quick insertion is used, then the operation speed improves, but the alignment precision deteriorates
Solution Approach 1:
The tapered cam slot and clocking key are pre-configured with specific geometric parameters (taper angles, slot dimensions, key positions) during manufacturing. This preliminary preparation enables the connector to automatically achieve high-precision alignment through simple insertion motion alone, eliminating the need for slow manual adjustment procedures. The pre-engineered geometry converts a potentially imprecise quick-insertion action into a high-precision alignment process, thereby maintaining both fast insertion speed and high alignment precision simultaneously.
Solution Approach 2:
The connector design enables self-alignment through the interaction between the tapered cam slot and clocking key. During insertion, the clocking key automatically engages the tapered cam slot, which guides the connector through quasi-helical motion that naturally positions the fiber cores aligned with laser spots. This self-service alignment mechanism occurs automatically during the insertion process itself, requiring no external alignment equipment or manual intervention, thereby achieving high precision while maintaining fast insertion speed.
3Ease of operation
If friction-resistant insertion is used, then the insertion force required decreases, but the alignment control precision may deteriorate
Solution Approach 1:
The tapered cam slot is pre-configured with specific surface properties and geometric parameters before insertion. The taper angle (15-30 degrees) and surface finish are predetermined to provide optimal friction characteristics. This preliminary configuration ensures that during insertion, the friction force naturally follows the tapered geometry to provide both low insertion resistance and precise alignment control. The pre-engineered friction characteristics prevent slippage while requiring minimal insertion force, thereby maintaining both ease of operation and alignment precision.
Solution Approach 2:
The patent utilizes parameter changes in the friction characteristics along the tapered cam slot. The normal force and friction force vary continuously along the taper angle during insertion. By carefully selecting the taper angle parameter (15-30 degrees), the system optimizes the balance between friction resistance (for alignment control) and insertion force requirement. This parameter optimization ensures that friction provides sufficient grip for precise alignment while not being so high as to require excessive insertion force, thereby maintaining both ease of operation and alignment precision.
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
The system achieves improved coupling efficiency and power uniformity by precisely aligning optical fibers with laser beams, enabling efficient transmission and reducing misalignment issues.
Implementation Method 1
a tapered surface disposed between the distal portion and the medial portion, the tapered surface configured to provide axial guidance during insertion of the optical fiber into the port adapter
Implementation Method 2
a clocking key disposed on an outer surface of the distal portion, the clocking key configured to facilitate quasi-helical guided rotation of the optical fiber during insertion into the port adaptor
Implementation Method 3
A sleeve is disposed within the medial portion of the barrel, the sleeve configured to provide a friction- and wear-resistant inner surface of the medial portion for high precision, lateral optical alignment of the fiber cores to the laser beam
Data Source
AI summary
Certain embodiments disclosed herein provide systems and devices for coupling optical fibers with laser surgical systems. In particular, certain aspects provide a push-pull connector and adapter for releasably coupling an optical fiber with a port of a laser surgical system. The connector and adapter facilitate mechanical lateral and rotational guidance of the optical fiber during insertion into the port to ensure proper alignment (e.g., clocking) of the optical fiber's cores with a laser beam pattern propagated by the laser surgical system. Accordingly, the connector and adaptor enable improved coupling efficiency between the laser beam pattern and one or more cores of the optical fiber, and therefore improved power uniformity between multiple laser beams transmitted through the cores.