Optical Fiber Laser Polishing for Custom End Faces
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Solution Overview
Problem
Current methods for cutting and polishing optical fibers are time and material-intensive, particularly for producing domed or rounded end face surfaces and off-axis surfaces, and lack general applicability for custom manufacturing.
Innovation Solution
A non-contact laser cutting and polishing method that involves positioning an optical fiber at a specific location and irradiating it with laser beams moving in a rotational direction to form a laser-processed end face, minimizing heat transfer and diameter growth by sweeping the laser beam across the fiber axis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical cutting and polishing process is used, then optical fibers can be processed with polished end faces, but the process is time and material-intensive and requires bulk processing
Solution Approach 1:
The patent replaces the mechanical cutting and polishing system with a laser-based system. The laser beam performs both cutting and polishing functions through optical energy, eliminating the need for mechanical contact between cutting/polishing tools and the fiber. This substitution enables single-fiber processing without the need for bulk processing, directly resolving the contradiction between ease of manufacture and productivity.
2Adaptability or versatility
If conventional laser cutting and polishing methods are used, then perpendicular flat or angled flat end face surfaces can be produced, but domed or rounded end face surfaces and off-axis surfaces cannot be produced
Solution Approach 1:
The patent introduces dynamic motion of the laser beam relative to the fiber axis. The laser beam is moved in a rotational direction around the fiber axis, and can be positioned at different radial distances from the axis. This dynamic positioning enables the laser to create domed, rounded, and off-axis flat surfaces by controlling the beam's rotational path and radial position, while maintaining high surface finish quality through precise motion control.
3Shape
If laser beams are stationary relative to the fiber axis, then simple flat surfaces can be produced, but domed or rounded surfaces cannot be formed
Solution Approach 1:
The patent employs periodic motion of the laser beam in a rotational direction around the fiber axis. This periodic sweeping action distributes the laser energy over time and space, preventing excessive heat concentration at any single point. The rotational motion creates the desired domed or rounded shapes through controlled melting and resolidification, while the periodic nature of the action manages heat transfer to acceptable levels.
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 enables efficient production of optical fibers with precise, high-quality end faces, including domed or rounded surfaces, reducing in-process inventory costs and allowing for custom manufacturing with excellent surface finish (less than 1 nm rms roughness).
Implementation Method 1
forming a laser processed end face on the individual fiber at said specific location by irradiating the individual fiber at said location with one or more laser beams
Implementation Method 2
forming a laser processed end face on the individual fiber at said specific location by irradiating the individual fiber at said location with one or more laser beams
Data Source
AI summary
A method is provided of fabricating an optical fiber having a polished end face, including providing an optical fiber having an axis; positioning and maintaining the axis A of the fiber, at a specific location along the fiber, at a fixed position; and forming a laser processed end face on the individual fiber at said specific location L by irradiating the individual fiber at said location with one or more laser beams while moving the one or more laser beams in a rotational direction around the fiber. The method may be applied to a jacketed fiber and/or a fiber on a reel. Resulting fibers are also disclosed.