Hybrid Optical Ferrule Assembly With Laser Welded Glass Insert
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Solution Overview
Problem
Optical ferrule assemblies face reliability issues due to misalignment and degradation caused by material properties and environmental loads, particularly when adhesives are present in the optical path.
Innovation Solution
The use of a hybrid optical ferrule assembly with a glass portion and a polymeric portion, where optical fibers are laser welded to the glass portion, eliminating adhesives from the optical path and enhancing alignment through a light redirecting mechanism, and the glass portion is designed to handle high power density light.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesives are used to attach optical fibers to the ferrule, then the fiber attachment process is simplified, but misalignment and degradation occur due to adhesive material properties and environmental loads
Solution Approach 1:
The patent removes adhesives from the optical path by using a hybrid ferrule structure where the glass portion directly receives and secures the optical fiber through mechanical engagement and environmental sealing, eliminating the adhesive layer that causes misalignment and degradation
Solution Approach 2:
The patent employs a hybrid ferrule combining polymeric and glass portions, where the glass portion provides optical transmission and fiber securing, while the polymeric portion provides structural support and environmental sealing, creating a composite structure that eliminates adhesives while maintaining ease of manufacture
2Ease of manufacture
If a single material is used for the entire ferrule, then manufacturing is simplified, but the ferrule cannot simultaneously handle high power density light and provide adequate structural support
Solution Approach 1:
The patent divides the ferrule into distinct functional segments: a glass portion for optical transmission and high power density handling, and a polymeric portion for structural support and environmental sealing, allowing each material to be optimized for its specific function
Solution Approach 2:
The patent applies different material properties to different regions of the ferrule based on functional requirements - the glass portion is positioned where high optical power density is present, while the polymeric portion provides structural support where mechanical strength is needed, creating local optimization of material properties
3Ease of manufacture
If adhesives are present in the optical path, then fiber attachment is easier, but thermal, moisture, and radiation-induced degradation occur
Solution Approach 1:
The patent extracts and removes adhesives from the optical path by implementing a hybrid ferrule structure where the glass portion directly secures the optical fiber through mechanical engagement, eliminating the adhesive layer that is susceptible to thermal, moisture, and radiation degradation
Solution Approach 2:
The patent introduces an intermediary hybrid structure between the optical fiber and the external environment, where the glass portion provides direct fiber securing and the polymeric portion provides environmental sealing, creating a protective interface that eliminates adhesive-related degradation while maintaining ease of manufacture
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 improves the reliability of optical ferrule assemblies by eliminating adhesive-related misalignment and degradation, ensuring precise alignment and efficient light transmission through the hybrid structure, which reduces thermal, moisture, and radiation-induced issues.
Implementation Method 1
a fiber end laser welded to the glass insert
Implementation Method 2
a light redirecting side for changing a direction of light received from the input surface
Data Source
AI summary
An optical ferrule assembly includes a hybrid optical ferrule having a glass portion assembled to a polymeric portion. The polymeric portion includes a groove for receiving and supporting an optical fiber having opposing open front and back ends. A light redirecting member includes an input surface for receiving light from the optical fiber and a light redirecting side. The open back end of the groove and the input surface define a recessed region therebetween. The glass portion includes an optically transparent glass insert disposed in the recessed region conforming in shape to an internal shape of the recessed region. An optical fiber is received and supported in the groove. The optical fiber includes a fiber end laser welded to the glass insert so that a central light ray from the optical fiber propagates through the glass insert before being received and redirected by the light redirecting side.