Fiber Optic Device Alignment Using Cleaved Angles and Lenses
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Solution Overview
Problem
The manufacturing of high-density fiber optic devices with multiple optical fibers is challenging due to alignment issues and increased costs, as existing technologies require precise alignment of numerous components, leading to longer manufacturing times and higher costs.
Innovation Solution
A method of forming fiber optic devices involves securing optical fibers to a support with alignment features, cleaving them at an angle greater than or equal to the critical angle, and coupling them to a base with optoelectronic devices using lenses or reflecting surfaces to achieve optical alignment, reducing the need for precise lateral alignment and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple optical fibers are combined in a small package to create high-density transceiver modules, then the device density and integration are improved, but the manufacturing complexity and alignment difficulty increase
Solution Approach 1:
The device is divided into separate functional modules: a support structure holding multiple optical fibers, a base holding multiple optoelectronic devices, and alignment reference features that segment the alignment task into coarse positioning and fine positioning stages. This segmentation allows high-density packaging while managing manufacturing complexity through modular assembly.
Solution Approach 2:
Alignment reference features are pre-formed on the support and base structures before final assembly. These features include alignment marks, positioning protrusions, and guide structures that are created during the manufacturing of individual components, enabling rapid and accurate alignment during final assembly without requiring complex real-time adjustment mechanisms.
2Manufacturing precision
If precise lateral alignment is required for multiple optical fibers and optoelectronic devices, then the optical coupling efficiency is improved, but the manufacturing time and cost increase
Solution Approach 1:
The support and base structures incorporate self-aligning features such as complementary geometric shapes, interference-fit protrusions and recesses, and gravity-assisted positioning elements. These features enable the components to automatically align with each other during assembly without requiring complex external alignment equipment or manual adjustment, achieving both high precision and fast manufacturing.
Solution Approach 2:
Alignment reference features act as intermediaries between the optical fibers and optoelectronic devices. These features include alignment marks that provide visual guidance, positioning pins that mechanically enforce alignment, and guide structures that constrain movement during assembly. The intermediaries translate the alignment requirement into simple mechanical or visual cues that speed up the manufacturing process.
3Reliability
If the optical fiber end angle is increased to meet the critical angle requirement for total internal reflection, then the optical coupling efficiency is improved, but the alignment tolerance decreases
Solution Approach 1:
The alignment system transitions from relying solely on lateral positioning to incorporating angular positioning through pre-formed fiber angles. By establishing the correct angle in the fiber fabrication stage rather than during assembly, the patent moves the precision requirement to an earlier manufacturing dimension where it can be controlled more easily, reducing the alignment tolerance burden during final assembly.
Solution Approach 2:
The patent specifies particular angle ranges (e.g., 45 degrees, 8 degrees to 15 degrees from perpendicular) that optimize the balance between achieving sufficient total internal reflection for good optical coupling and maintaining reasonable alignment tolerances. These parameter changes are built into the fiber construction process rather than requiring post-processing adjustment.
4Productivity
If adjustable tolerances are reduced to improve manufacturing speed and cost, then the manufacturing efficiency is improved, but the design flexibility decreases
Solution Approach 1:
The support and base structures are designed with universal alignment reference features that can accommodate different configurations of optical fibers and optoelectronic devices. The same basic structure with standardized alignment features can be used for various device densities, fiber types, and optoelectronic component arrangements, maintaining design flexibility while enabling efficient manufacturing with fixed tolerances.
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 approach reduces manufacturing complexity and costs by allowing for quicker and more accurate construction of fiber optic devices with fewer alignment requirements, improving optical efficiency and reducing the risk of misalignment.
Implementation Method 1
The angle of the end of one or more of the optical fibers is greater than or equal to the critical angle formed between an optoelectronic device that is optically coupled to the optical fiber
Implementation Method 2
one or more lenses molded as a portion of the support. One or more of the optical fibers are positioned in optical alignment with one or more of the lenses
Implementation Method 3
one or more reflecting surfaces molded as a portion of the support. One or more of the optoelectronic devices are optically coupled to one or more of the optical fibers through the one or more reflecting surfaces
Data Source
AI summary
A fiber optic device includes a support having one or more optical fibers coupled to the support and a base that includes one or more optoelectronic devices. The support is coupled to the base such that one or more of the optoelectronic devices are optically coupled to one or more of the optical fibers. A portion of the one or more optical fibers that is in contact with the support may be bent and one or more of the optoelectronic devices may be optically coupled to the bent portion of one or more of the optical fibers.