Fiber Pigtail Integrated Polymer Lid for Automated Assembly
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Solution Overview
Problem
The assembly of fiber pigtails to substrates is complex and costly due to the need for precise alignment of individual fibers within grooves, requiring two mechanical arms and manual placement, which limits automation and increases costs.
Innovation Solution
A fiber pigtail with an integrated polymer lid that allows for accurate spacing and attachment of bare fibers, enabling single-arm assembly using standard microelectronic packaging tools, simplifying the process and reducing costs by eliminating the need for separate mechanical arms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual fibers are manually placed within grooves using two mechanical arms, then precise alignment is achieved, but assembly complexity and cost increase
Solution Approach 1:
The polymer lid is integrated with the fiber pigtail to form a single unified component. This integration eliminates the need for separate alignment fixtures and mechanical arms, as the lid itself provides the structural framework for precise fiber positioning through its molded features
Solution Approach 2:
The polymer lid incorporates built-in alignment features such as molded grooves and positioning structures that automatically guide fiber placement. The lid serves its own alignment function without requiring external alignment equipment, enabling self-alignment during assembly
2Manufacturing precision
If two mechanical arms are used for fiber placement, then accurate positioning is achieved, but automation capability is limited
Solution Approach 1:
The polymer lid's integrated alignment features enable the assembly process to be self-guiding, allowing standard automated pick-and-place equipment to position fibers accurately without requiring complex dual-arm coordination or manual intervention for alignment
3Manufacturing precision
If manual placement with two mechanical arms is used, then fiber alignment is precise, but assembly cost increases
Solution Approach 1:
By combining the polymer lid and fiber pigtail into one integrated component, the patent eliminates the need for expensive dual-arm mechanical alignment systems and manual placement operations, significantly reducing assembly equipment investment and operational costs
Solution Approach 2:
The self-aligning features of the integrated lid reduce the skill level and time required for assembly operations, lowering labor costs and enabling the use of more economical automated equipment instead of expensive specialized machinery
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 integrated polymer lid simplifies the assembly process, improves placement accuracy, and reduces costs by allowing automated assembly with standard tools, while maintaining precise fiber spacing and alignment for optical coupling.
Implementation Method 1
placing a polymer lid with an adhesive layer on the fiber optic ribbon end
Data Source
AI summary
A mechanism is provided for a fiber pigtail. The fiber pigtail includes a single mode fiber optic ribbon having a section of polymer ribbon removed to expose bare fibers, a fiber optic ferrule in contact with the single mode fiber optic ribbon at one distal end, and an integrated polymer lid permanently attached to the bare fibers of the single mode fiber optic ribbon at another distal end of the single mode fiber optic ribbon.