Laser Processing of Arrayed Optical Fibers Using Protection Elements

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Solution Overview

Problem

The increasing demand for high fiber count fiber optic connectors poses a challenge due to the difficulty in aligning the small cores of optical fibers with suitable transmission loss levels, especially as the fiber count increases, making it hard to achieve efficient and reliable connections.

Innovation Solution

The method involves laser processing of optical fibers using a protection element that reflects, absorbs, or disperses laser energy to prevent damage to unprocessed fibers, allowing for efficient alignment and connection of multiple fibers through the use of adapters with fiber guides and index-matching materials or lenses for high-density optical connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If the fiber count in fiber optic connectors is increased to meet bandwidth demands, then the transmission capacity is improved, but the alignment difficulty and manufacturing complexity increase significantly

Engineering Contradiction:

Improvefiber countVSAvoidalignment precision

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The connector is divided into multiple precision-machined alignment features including ferrule bores, fiber position features, and registration features that segment the alignment process into controlled stages, enabling high fiber count connections while maintaining alignment precision

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention employs precise dimensional parameters and tolerances in the alignment features (ferrule bore diameters, fiber position tolerances, registration feature dimensions) to achieve and maintain alignment precision across high fiber count connectors

Inventive Principle:

Principle #35Parameter changes

2Quantity of substance

If the number of fibers in the array is increased, then the bandwidth capacity is improved, but the difficulty of aligning small cores with suitable transmission loss levels increases

Engineering Contradiction:

Improvenumber of fibersVSAvoidtransmission loss level

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

Each fiber position feature and ferrule bore is designed with specific local geometric properties and tolerances to ensure precise fiber alignment and consistent transmission loss characteristics across all fibers in the high-density array

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention replaces manual alignment methods with laser-based processing and precision-machined alignment features, enabling consistent alignment and transmission loss control that cannot be achieved through mechanical means alone

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If traditional methods are used to align and connect high fiber count arrays, then the process becomes increasingly difficult and time-consuming, but the connection quality must be maintained

Engineering Contradiction:

Improveconnection speedVSAvoidalignment precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Alignment features including ferrule bores, fiber position features, and registration features are pre-formed with precise dimensions during manufacturing, eliminating the need for time-consuming alignment adjustments during assembly while maintaining high connection quality

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Laser processing replaces traditional mechanical alignment and connection methods, enabling faster processing while maintaining or improving alignment precision through controlled energy delivery and precision positioning

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 approach enables quick, economical, and high-quality connections among large numbers of optical fibers, improving alignment and reducing transmission loss, thus facilitating the creation of high-fiber count connectors with increased efficiency and reliability.

Implementation Method 1

laser processing the first row of optical fibers

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

inserting a protection element adjacent to the optical fibers

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 3

protection element that reflects, absorbs, or disperses laser energy

Methodology Applied

Scientific EffectAbsorption (EM radiation): Absorption (EM radiation)

Data Source

PatentUS9268091B2Methods for laser processing arrayed optical fibers along with splicing connectors

Publication Date: 2016.02.23 CORNING OPTICAL COMMUNICATIONS LLC

AI summary

A method for laser processing arrays of optical fibers and high-fiber count splicing connectors and adapters are disclosed. The method includes the steps of providing a structure having optical fibers arranged in a plurality of rows and placing a protection element adjacent to a first row of optical fibers and a second row of optical fibers. Thereafter, the first row of optical fibers can be processed using the laser. The protection element may also be used to move optical fibers. In one embodiment, the protection element has a first portion and a second portion that have relative movement therebetween. In other variations, an absorption element may be provided adjacent the first row of optical fibers for inhibiting incidental damage to the structure.