High-density optical fiber array with multilayer positioning
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Solution Overview
Problem
Conventional optical fiber arrays are costly, cumbersome, and inefficient, posing challenges in terms of precision, assembly difficulty, and reliability.
Innovation Solution
A high-density two-dimensional optical fiber array system is developed, utilizing a multilayer positioning sheet stack with precisely aligned holes and a guide hole array block, allowing for precise fiber alignment and assembly, with the option of glue-free bonding and the use of materials like monocrystalline silicon, to reduce complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional optical fiber array systems are used, then fiber alignment can be achieved, but the system becomes costly and cumbersome with reduced efficiency
Solution Approach 1:
The positioning system is segmented into multiple independent layers (first positioning sheet with first holes, second positioning sheet with second holes, etc.), where each layer performs a specific positioning function. This segmentation allows for modular manufacturing and assembly while maintaining high alignment precision, reducing overall system complexity.
Solution Approach 2:
The invention transitions from conventional single-plane positioning to multi-layer three-dimensional positioning. By stacking multiple positioning sheets with holes at different depths and configurations, the system achieves precise fiber alignment through vertical dimension control, enabling high-density arrangements that are not possible with single-plane methods.
2Quantity of substance
If high-density fiber arrays are formed, then fiber capacity increases, but assembly difficulty and cost increase
Solution Approach 1:
Fibers are pre-positioned within the multilayer positioning structure before final assembly. The holes in each positioning sheet are pre-configured with specific diameters and positions to guide fiber placement, and adhesives are pre-applied to securing locations. This preliminary action simplifies the final assembly process while enabling high-density fiber arrangements.
Solution Approach 2:
Multiple positioning sheets act as intermediary structures between the fiber bundle and the final array configuration. Each sheet with its pattern of holes serves as a mediator that gradually guides and constrains fibers into their precise final positions, making the complex task of high-density assembly manageable through stepwise positioning.
3Manufacturing precision
If precise fiber alignment is achieved through conventional methods, then alignment accuracy is maintained, but assembly time and complexity increase
Solution Approach 1:
Multiple positioning functions are merged into a single integrated multilayer structure. The first positioning sheet, second positioning sheet, and subsequent layers are combined in a stacked configuration, where each layer contributes to the overall positioning accuracy. This merging eliminates the need for separate positioning operations, reducing assembly time while maintaining high alignment accuracy.
Solution Approach 2:
The positioning sheets are pre-configured with holes of varying diameters and patterns optimized for specific fiber types and densities. Adhesives are pre-applied to designated securing locations on each layer. This preliminary preparation allows for rapid assembly without compromising alignment precision, as the positioning geometry is already optimized before the fiber insertion process begins.
Data Source
AI summary
An optical fiber array device, where the optical fiber array device comprises a fiber base flange, enabled to hold an integrated positioning sheet. The integrated positioning sheet comprises a plurality of channels, with each formed by at least a positioning hole and a tapered hole. A plurality of fibers or fiber bundles are fixed in the positioning holes of the integrated positioning sheet. The device further comprises a lens array, with each lens of the lens array aligned with one channel of the plurality of channels.