Lens-Based Optical Connector Alignment for High Fiber Counts
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Solution Overview
Problem
Current optical connector technologies face challenges in precisely aligning large numbers of optical fibers due to the need for sub-micron accuracy and high axial forces, which is beyond the capability of existing manufacturing processes, especially for connectors with 96 or more fibers, and existing methods are costly and time-consuming.
Innovation Solution
A lens-based connector assembly with a glass-based optical substrate featuring alignment features formed by a laser process, where the alignment features are located within 0.4 μm of the optical elements, and a method of fabricating these substrates using laser damage and etching to create precise alignment features, reducing processing time and cost by combining coarse and fine processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional connector molding processes are used for high fiber-count connectors (96 or more fibers), then manufacturing complexity increases beyond current capabilities, but manufacturing precision cannot be achieved (position errors smaller than 1 μm are required)
Solution Approach 1:
The invention divides the complex task of creating a high-precision fiber array into separate functional components: a ferrule that provides mechanical support and alignment features, and precisely positioned fibers within the ferrule. This segmentation allows each component to be manufactured and aligned independently, achieving the required sub-micron precision without requiring the entire connector to be molded as a single complex piece.
2Quantity of substance
If the number of fibers in a connector is increased to 96 or more, then fiber count capacity improves, but the precision requirements for fiber positioning and contact become unachievable with current technologies
Solution Approach 1:
The invention implements self-aligning features where the ferrule structure itself provides alignment references through precisely positioned protrusions that engage with corresponding recesses in the connector body. This self-service alignment mechanism automatically ensures correct fiber positioning without requiring external alignment tools or complex adjustment procedures, enabling high fiber-count connectors to achieve the required precision.
3Reliability
If traditional fusion splicing is used to join hundreds of optical fibers, then connection reliability improves with low optical loss, but processing time and cost increase significantly
Solution Approach 1:
The invention performs preliminary alignment and positioning of all fibers within the ferrule before the final connector assembly. The ferrule is pre-configured with precisely positioned fibers and alignment features that ensure correct positioning upon insertion. This preliminary action eliminates the need for time-consuming field splicing operations, significantly improving processing speed while maintaining connection reliability through the pre-established precise fiber alignment.
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
The solution enables precise alignment of high fiber count connectors with reduced processing time and cost, achieving accurate optical coupling and overcoming the limitations of existing technologies in precision and manufacturing efficiency.
Implementation Method 1
forming at least one laser damage area within a glass sheet by applying a laser beam to the glass sheet
Implementation Method 2
etching the glass sheet in an etching solution to remove a portion of the glass-based optical substrate, thereby defining the at least one alignment feature
Data Source
AI summary
Lens-based optical connector assemblies and methods of fabricating the same are disclosed. In one embodiment, a lens-based connector assembly includes a glass-based optical substrate includes at least one optical element within the optical substrate, and at least one alignment feature positioned at an edge of the glass-based optical substrate, wherein the at least one alignment feature is located within 0.4 μm of a predetermined position with respect to the at least one optical element along an x-direction and a y-direction. The lens-based connector assembly further includes a connector element including a recess having an interior surface, The interior surface has at least one connector alignment feature. The glass-based optical substrate is disposed within the recess such that the at least one alignment feature of the glass-based optical substrate engages the at least one connector alignment feature.