Hexagonal Fastener Channel for Optical Fiber Bundle Coupling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current ferrules used for coupling optical fiber bundles result in low interfacing percentages, leading to light loss and the need for more powerful light sources, which generate excessive heat.
Innovation Solution
A fastener system with a channel configured to secure fibers in a packing configuration, allowing for the creation of two fiber bundles with matching packing configurations that can be efficiently coupled, reducing lateral offset and improving optical axis alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional ferrules are used for coupling optical fiber bundles, then the coupling process is simple, but the interfacing percentage is low resulting in light loss
Solution Approach 1:
The patent applies preliminary action by pre-organizing fibers into bundles with specific packing configurations (hexagonal, square, or circular) before coupling. The fastener system pre-aligns and secures fibers in a predetermined pattern, ensuring that when bundles are coupled, the fibers are already positioned for optimal interfacing. This preliminary organization eliminates the need for complex real-time alignment during coupling and maximizes the interfacing percentage.
Solution Approach 2:
The patent changes the packing configuration parameter of fiber bundles from random or conventional arrangements to specific geometric patterns (hexagonal, square, or circular packing). This parameter change in fiber arrangement enables better geometric matching at coupling interfaces, directly improving interfacing percentage and reducing light loss. The fastener system is designed with channels that enforce these specific packing configurations.
2Illumination intensity
If more powerful light sources are used to compensate for light loss, then illumination intensity is improved, but heat generation increases
Solution Approach 1:
The patent converts the harmful effect of light loss into a benefit by using the fastener system to achieve such high interfacing percentages that the original problem of light loss is eliminated. Instead of compensating for losses with more powerful (and hotter) light sources, the system's improved coupling efficiency naturally provides sufficient illumination while avoiding the heat generation problem associated with high-power sources.
3Ease of operation
If fibers are loosely arranged in the fastener system, then ease of insertion is improved, but packing efficiency and alignment precision decrease
Solution Approach 1:
The patent applies segmentation by dividing the fiber bundle into individual fibers that are separately received by the fastener system's channel. Each fiber is independently positioned and secured within the channel, allowing for precise control of each fiber's position while maintaining ease of insertion. The channel's geometry guides and constrains fibers into the desired packing configuration without requiring complex manipulation.
Solution Approach 2:
The fastener system acts as an intermediary between the loose fiber ends and the final coupled bundle. The channel within the fastener serves as a mediator that receives fibers in a loose state and transforms them into a precisely packed configuration through its geometric constraints. This intermediary structure enables both easy insertion and high alignment precision.
Data Source
AI summary
An apparatus comprises a first fastener part having a first set of mating features and a second fastener part having a second set of mating features. Coupling the first set of mating features with the second set of mating features, such that the first set of mating features contacts and at least partially overlaps the second set of mating features, forms a fastener having a channel with a hexagonal cross-section. The channel is configured to receive a plurality of fibers. Coupling the first fastener part to the second fastener part clamps the plurality of fibers in a hexagonal packing configuration.