Multi-layer Monolithic Fiber Optic Alignment Structures
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Solution Overview
Problem
There is a need for improved fiber optic alignment devices that can efficiently align multiple fibers side to side, end to end, or in two axes perpendicular to the fiber's longitudinal axis, with enhanced positioning and orientation capabilities, particularly in the field of fiber optics, where existing solutions lack versatility and cost-effectiveness.
Innovation Solution
The development of a fiber optic alignment device comprising multiple layers with entry ports, insertion channels, side alignment features, and spring elements that force inserted fibers into precise alignment positions, allowing for passive alignment and secure retention without damaging the fibers, and the use of electrochemical fabrication techniques to create these devices with precise multi-layer structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional fiber optic alignment devices are used, then fiber alignment can be achieved, but the devices lack versatility for multiple alignment configurations and are costly
Solution Approach 1:
The alignment device is divided into multiple discrete layers (first layer, second layer, third layer) that can be independently fabricated and then assembled. Each layer contains specific alignment features (entry ports, insertion channels, side alignment features, retention features) that can be selectively designed and manufactured using electrochemical fabrication techniques, allowing versatile alignment configurations while maintaining cost-effectiveness through modular production
Solution Approach 2:
The multi-layer structure provides universal alignment capabilities for multiple fiber optic configurations including side-by-side alignment, end-to-end alignment, and angled alignment. The device can accommodate different fiber types and applications through its standardized yet flexible feature set, eliminating the need for multiple specialized alignment devices and reducing overall fabrication costs
2Measurement precision
If precise alignment features are incorporated into the device, then fiber alignment precision is improved, but the device structure becomes more complex
Solution Approach 1:
Complex alignment features are segmented across multiple layers rather than attempting to create all features in a single monolithic structure. The first layer provides entry ports and initial alignment features, the second layer provides insertion channels and side alignment features, and the third layer provides retention features. This segmentation simplifies the fabrication of each individual layer while achieving precise overall alignment through layer assembly
Solution Approach 2:
The alignment device transitions from two-dimensional planar features to three-dimensional multi-layer structures. By adding the vertical dimension through layer stacking, the device achieves precise alignment in multiple axes (x, y, and z) simultaneously. The layered approach allows alignment features to be positioned in three-dimensional space, providing precise fiber positioning without requiring overly complex single-plane geometries
3Productivity
If electrochemical fabrication techniques are used, then fabrication time and cost are reduced, but manufacturing precision must be maintained
Solution Approach 1:
Each layer is pre-designed with specific alignment features (entry ports, insertion channels, side alignment features, retention features) that are fabricated using electrochemical techniques before assembly. The electrochemical fabrication process deposits materials layer-by-layer with controlled thickness and geometry, ensuring that each layer meets precision requirements before being combined with other layers. This preliminary fabrication of individual layers maintains manufacturing precision while enabling rapid overall production
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 solution provides improved alignment and retention of fiber optic elements with reduced fabrication costs and times, increased versatility in device design, and enhanced material properties, enabling more efficient and cost-effective production of fiber optic alignment devices with precise geometric configurations.
Implementation Method 1
at least one spring element, for each insertion channel, that forces an inserted fiber optic element into an alignment position
Implementation Method 2
An electrochemical fabrication technique for forming three-dimensional structures from a plurality of adhered layers has been and is being commercially pursued
Data Source
AI summary
Embodiments of the present invention are directed to fiber optic element devices, methods for aligning fiber optic elements, and batch formation methods for creating such fiber optic alignment devices.