GRIN Lens Chip Alignment Grooves for Fiber Optic Connectors
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Solution Overview
Problem
Existing fiber optic connector designs face challenges in precisely aligning gradient index (GRIN) lenses within ferrules, leading to optical attenuation and increased manufacturing costs due to the need for specialized equipment and complex alignment processes, especially in consumer devices with limited space.
Innovation Solution
The use of GRIN lens chips with integrated alignment grooves and a modular design allows for precise alignment of GRIN lenses relative to optical fibers, reducing optical attenuation and manufacturing complexity by simplifying the alignment process and reducing the number of optical interfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If GRIN lenses are positioned precisely within the ferrule using conventional methods, then alignment accuracy is improved, but manufacturing cost and device complexity increase due to specialized equipment and complex alignment processes
Solution Approach 1:
The patent applies preliminary action by pre-forming alignment grooves directly into the ferrule structure before GRIN lens insertion. These grooves are created in advance to guide and position the GRIN lenses at precise locations, eliminating the need for complex real-time alignment equipment during assembly. The grooves serve as pre-prepared guides that automatically position the lenses correctly when inserted.
Solution Approach 2:
The alignment grooves act as an intermediary element between the ferrule and the GRIN lenses. Instead of directly positioning the lenses within the ferrule cavity, the grooves mediate the positioning process by providing a physical guide structure that constrains the lenses to correct positions, simplifying the overall alignment process.
2Manufacturing precision
If GRIN lenses are positioned precisely within the ferrule using conventional methods, then alignment accuracy is improved, but manufacturing cost increases due to specialized equipment
Solution Approach 1:
The alignment grooves are pre-formed into the ferrule structure using conventional manufacturing techniques before the GRIN lenses are inserted. This preliminary preparation eliminates the need for expensive specialized alignment equipment during the lens positioning process, reducing manufacturing costs while maintaining precision.
Solution Approach 2:
The ferrule structure provides self-alignment functionality through the integrated alignment grooves. The grooves automatically guide the GRIN lenses into correct positions without requiring external specialized equipment or complex alignment procedures, making the manufacturing process more economical and accessible.
3Manufacturing precision
If the ferrule size is increased to accommodate features for precise GRIN lens positioning, then alignment accuracy is improved, but the connector size increases which is prohibitive for consumer markets
Solution Approach 1:
Instead of increasing the overall ferrule size, the patent applies local quality by creating localized alignment grooves only at the specific positions where GRIN lenses need to be positioned. This approach provides precise alignment functionality only where needed, without increasing the overall volume of the ferrule or connector, making it suitable for compact consumer devices.
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 solution enables more reliable and efficient alignment of GRIN lenses, minimizing optical attenuation and lowering manufacturing costs by simplifying the alignment process and reducing the complexity of optical interfaces, making it suitable for consumer applications.
Implementation Method 1
GRIN lenses focus light through a precisely controlled radial variation of the lens material's index of refraction from the optical axis, typically at the center axis, to the edge of the lens
Data Source
AI summary
Gradient index (GRIN) lens chips and associated small form factor optical arrays for optical connections, and related fiber optic connectors are disclosed. By aligning GRIN lenses within a GRIN lens chip, a more precise and reliable alignment may be achieved with respect to optical fibers than if a single conventional ferrule is utilized to align and secure both GRIN lenses and optical fibers. The GRIN lens chip may include a GRIN lens received and thereby aligned within a groove disposed between a fiber end and a terminal end of a GRIN lens holder body. The optical fibers may also be received and thereby aligned within a groove of a ferrule body. In this manner, when the GRIN lens chip containing the GRIN lenses is aligned with a ferrule body containing the optical fibers, then the GRIN lenses may be precisely located relative to the optical fibers.