Hermetic Optical Fiber Alignment Assembly with Integrated Reflective Element
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Solution Overview
Problem
Existing hermetic optical fiber alignment assemblies are bulky, expensive, and complex, with poor manufacturability and reliability, due to the need for precise sub-micron alignment and handling of brittle optical fibers, which results in high costs and increased size, especially in multi-channel fiber transmission systems.
Innovation Solution
A hermetic optical fiber feedthrough assembly using a dual-ferrule structure with alignment grooves and a cavity sealed with a sealant, where the ferrule portions are attached with a pocket and aperture for precise alignment and sealing, allowing for integrated optical elements like reflective surfaces for improved alignment and reduced complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a cylindrical sleeve with large clearance is used for hermetic feedthrough, then the optical fiber can pass through easily, but the assembly becomes bulky and the optical alignment precision deteriorates
Solution Approach 1:
The cylindrical sleeve is segmented into multiple ferrule portions (first ferrule portion, second ferrule portion, third ferrule portion) with distinct functions. The first ferrule portion provides hermetic sealing with the housing, the second ferrule portion contains precision alignment grooves for optical fibers, and the third ferrule portion extends into the housing to support optical elements. This segmentation allows each portion to be optimized for its specific function, achieving both ease of insertion and high alignment precision.
Solution Approach 2:
The invention transitions from a simple cylindrical sleeve to a multi-dimensional ferrule structure with grooves extending in multiple directions. The alignment grooves are positioned at specific depths and angles to precisely locate optical fibers in three-dimensional space, enabling sub-micron alignment precision while maintaining a compact form factor.
2Reliability
If a separate ferrule and sleeve structure is used, then the optical fiber can be sealed, but the device complexity and cost increase
Solution Approach 1:
The invention merges the hermetic sealing function and the optical alignment function into a single integrated ferrule assembly. The first ferrule portion provides hermetic sealing with the housing, while the second and third ferrule portions provide precision alignment for optical fibers and elements. This integration eliminates the need for separate ferrule and sleeve components, reducing assembly complexity and cost while maintaining reliable hermetic sealing.
Solution Approach 2:
The ferrule assembly serves multiple functions simultaneously: it provides hermetic sealing against the housing, aligns multiple optical fibers with precise grooves, supports optical elements within the housing, and maintains structural integrity. This multi-functionality reduces the overall component count and simplifies the device architecture.
3Reliability
If traditional hermetic feedthrough structures are used, then the opto-electronic devices are protected, but the assembly size increases making it unsuitable for smaller devices
Solution Approach 1:
The ferrule portions are designed with thin-walled yet structurally sound geometry that provides hermetic protection while minimizing volume. The precision grooves are formed directly in the ferrule walls, eliminating the need for additional alignment structures that would increase size. This allows the assembly to maintain environmental protection in a compact form factor suitable for smaller devices.
Data Source
Figure 1
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Figure 4A~4C
AI summary
A hermetic optical fiber alignment assembly includes a ferrule portion (40) having a plurality of grooves (34) receiving the end sections of optical fibers, wherein the grooves define the location and orientation of the end sections with respect to the ferrule portion. The assembly includes an integrated optical element for coupling the input/output of an optical fiber to the opto-electronic devices in the opto-electronic module. The optical element can be in the form of a structured reflective surface. The end of the optical fiber is at a defined distance to and aligned with the structured reflective surface. The structured reflective surfaces and the fiber alignment grooves can be formed by stamping.