Interdigitated Fiber Array Assembly with Pusher for Precision Alignment
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Solution Overview
Problem
Conventional methods for manufacturing multifiber connectors are costly and time-consuming due to the need for expensive machine tools to achieve submicron accuracy in aligning optical fibers, which is essential for efficient optical interconnections.
Innovation Solution
A fiber array assembly is formed using a support substrate with an interdigitated signal fiber array, a fiber pusher device, and a cover sheet, where the interdigitated signal fibers are secured within a ferrule to ensure precise alignment and connection, utilizing glass materials for both the substrate and cover sheet to facilitate low-cost and efficient manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional V-groove substrate machining methods are used to achieve submicron alignment precision, then manufacturing precision is improved, but device complexity and manufacturing cost increase due to expensive machine tools
Solution Approach 1:
The patent replaces expensive, complex V-groove substrates with simple glass plates that are inexpensive and easy to manufacture. The glass plates are used once to define the ferrule geometry and alignment features, then discarded, eliminating the need for costly precision machine tools while maintaining submicron alignment precision through the molded ferrule structure.
Solution Approach 2:
The patent substitutes mechanical machining processes with injection molding technology. Instead of using precision machine tools to carve V-grooves into substrates, the alignment features and ferrule geometry are created through molded plastic structures, dramatically simplifying the manufacturing system while preserving alignment accuracy.
2Manufacturing precision
If conventional V-groove substrate machining methods are used to achieve submicron alignment precision, then manufacturing precision is improved, but manufacturing time increases due to time-consuming fabrication processes
Solution Approach 1:
The patent incorporates alignment features directly into the mold design, so that precise alignment structures are created during the injection molding process itself. The molded ferrule includes pre-formed alignment pins, grooves, and features that ensure submicron precision without requiring subsequent time-consuming machining or assembly operations.
Solution Approach 2:
The patent changes the manufacturing parameter from mechanical machining to injection molding, which allows for faster production cycles. The molded ferrule structure achieves the same alignment precision as machined V-grooves but is produced in a fraction of the time through high-speed molding processes.
3Manufacturing precision
If conventional V-groove substrate methods are used, then alignment precision is maintained, but manufacturing cost increases due to expensive machine tools and fabrication processes
Solution Approach 1:
The patent replaces expensive, reusable V-groove substrates and precision machine tools with inexpensive, disposable glass plates and injection molding equipment. The glass plates are simple, low-cost items that define ferrule geometry without requiring precision machining, dramatically reducing capital equipment costs while maintaining alignment precision through the molded structure.
Solution Approach 2:
The patent uses the glass plate as a template or copy to define the ferrule geometry and alignment features. The injection molding process creates precise replicas of the alignment structures defined by the simple glass plate, transferring the alignment precision from a low-cost template to the production parts without requiring expensive machining of each individual component.
Data Source
AI summary
The fiber array assemblies include an interdigitated signal-fiber array supported on a support substrate and formed by front-end sections of first signal fibers interdigitated with either front-end sections of second signal fibers or spacer fibers. The assemblies also include a fiber pusher device that may comprise glass and first and second ends. The fiber pusher device is disposed so that its first and second ends contact and push against first and second edges of the interdigitated signal-fiber array to remove gaps between adjacent signal fibers. A cover sheet is disposed atop the interdigitated signal-fiber array and covers at least a portion of the fiber pusher device to define a ferrule. A securing material is disposed within a ferrule interior to secure the cover sheet, the interdigitated signal-fiber array and the fiber pusher devices. The fiber array assemblies can be connectorized by adding an interconnect device or the like.