Self-aligning Fiber Optic Connector Microlens
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Solution Overview
Problem
Conventional optical fiber connectors require tight manufacturing tolerances to avoid air interfaces, leading to high production costs and complexity, while also needing mechanisms for self-alignment of fiber cores with microlenses for efficient light transmission.
Innovation Solution
A fiber optical connector microlens with a self-aligning optical fiber cavity, featuring a convex first lens surface and a second lens surface with an integrally formed fiber alignment cavity, cradle, or tube, which allows for mechanical securing and alignment with the optical fiber core, reducing the need for precise manufacturing tolerances and enabling efficient light focusing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If tight manufacturing tolerances are used to avoid air interfaces, then connector loss is reduced, but manufacturing cost and complexity increase
Solution Approach 1:
The patent introduces a microlens as an intermediary optical element between the fiber core and the air interface. The microlens focuses light onto the fiber core while allowing a larger air gap, thereby reducing the impact of misalignment and interface reflections on connector loss without requiring tight manufacturing tolerances
Solution Approach 2:
The patent changes the optical parameters by introducing a microlens with specific focal length and curvature radius. This allows the system to tolerate larger misalignments and air gaps while maintaining low connector loss, effectively decoupling the performance from tight manufacturing tolerances
2Reliability
If tight manufacturing tolerances are used to align fiber core with microlens, then coupling efficiency is improved, but production cost increases
Solution Approach 1:
The patent implements a self-aligning mechanism where the fiber core automatically positions itself relative to the microlens through a V-groove structure. The fiber is inserted into the V-groove which guides it to the optimal position, eliminating the need for precise pre-alignment and reducing manufacturing costs while maintaining high coupling efficiency
Solution Approach 2:
The V-groove acts as an intermediary alignment structure that mediates between the fiber and microlens. It provides a mechanical guide that ensures proper alignment without requiring tight tolerances in the microlens positioning, thereby reducing production complexity
3Loss of energy
If direct glass to glass contact is used, then air interface loss is eliminated, but manufacturing precision requirements increase
Solution Approach 1:
The patent introduces a microlens as an intermediary element that allows light to be focused through an air gap rather than requiring direct contact. This eliminates the need for precise glass-to-glass alignment while maintaining low loss by focusing the light beam onto the fiber core through the air interface
Solution Approach 2:
Instead of eliminating the air interface through direct contact, the patent inverts the approach by accepting the air interface but using a microlens to focus light through it. This transforms the problem from avoiding air interfaces to managing light propagation through them, thereby reducing manufacturing precision requirements
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 self-aligning mechanism reduces manufacturing costs and complexity by allowing for laxer tolerances while maintaining high coupling efficiency and effective light transmission, even with minor misalignments, thus improving the overall performance and affordability of optical connectors.
Implementation Method 1
The microlens includes a convex first lens surface and a second lens surface with an integrally formed fiber alignment cavity
Data Source
AI summary
A fiber optical connector microlens is provided with a self-aligning optical fiber cavity. The microlens includes a convex first lens surface and a second lens surface. A fiber alignment cavity is integrally formed with the second lens surface to accept an optical fiber core. A lens body is interposed between the first and second lens surfaces, having a cross-sectional area with a lens center axis, and the fiber alignment cavity is aligned with the lens center axis. In a first aspect, the fiber alignment cavity penetrates the lens second surface. In a second aspect, an integrally formed cradle with a cradle surface extends from the lens second surface, and a channel is formed in the cradle surface, with a center axis aligned with the lens center axis. The fiber alignment cavity includes a bridge covering a portion of the channel.