Lidless Fiber Array Units Using Adhesive Profiles for Passive Alignment
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Solution Overview
Problem
Conventional methods for achieving precision alignment of optical fibers in multifiber connectors are expensive and time-consuming, requiring costly machine tools and glass V-groove substrates, which limits the cost-effectiveness and efficiency of high-density fiber array units (FAUs) for optical interconnections.
Innovation Solution
The development of lidless fiber array units (FAUs) using a squeeze technology that eliminates the need for glass V-groove substrates, employing an integral support sheet with UV-curable adhesive for precise alignment of optical fibers, allowing for compact, high-density interconnections with reduced material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If glass V-groove substrates are used for fiber alignment, then alignment precision is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent extracts the alignment function from the complex glass V-groove substrate structure and implements it through a simpler support substrate with adhesive-based positioning. The adhesive profile carries the alignment function that previously required精密 V-groove machining, thereby simplifying the overall device structure while maintaining alignment precision.
Solution Approach 2:
The patent replaces expensive, difficult-to-manufacture glass V-groove substrates with a more economical support substrate and adhesive system. This substitution uses cheaper materials and simpler manufacturing processes to achieve the same alignment function, reducing both material cost and manufacturing complexity.
2Manufacturing precision
If glass V-groove substrates are used for fiber alignment, then alignment precision is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent replaces the mechanical V-groove machining system with an adhesive-based positioning system. Instead of using precision mechanical tools to machine V-grooves into glass substrates, the invention uses UV-curable adhesive profiles to position fibers, significantly simplifying the manufacturing process and reducing both time and cost.
Solution Approach 2:
The patent changes the fundamental parameter of alignment from mechanical contact in V-grooves to chemical bonding via adhesive. This parameter change from mechanical to chemical positioning enables simpler manufacturing while maintaining the required alignment precision for optical fiber connections.
3Manufacturing precision
If conventional fiber connector methods are used, then alignment precision is achieved, but manufacturing efficiency decreases
Solution Approach 1:
The patent applies preliminary action by pre-forming adhesive profiles on the support substrate before fiber placement. This allows multiple fibers to be positioned and bonded simultaneously in a single operation, rather than requiring sequential alignment and bonding operations, thereby significantly improving manufacturing efficiency while maintaining precision.
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 accurate passive alignment of optical fibers with reduced material costs and increased manufacturing efficiency, making high-density optical interconnections more practical and cost-effective for applications like data center switches and photonic integrated circuits.
Implementation Method 1
The adhesive may be a UV-curable adhesive which is cured by applying ultraviolet (UV) light
Data Source
AI summary
A fiber optic assembly is provided including a support substrate having a substantially planar surface, a signal-fiber array supported on the planar surface of the support substrate. The signal-fiber array including a plurality of optical fibers and an adhesive disposed on the plurality of optical fibers and the support substrate. Each of the optical fibers is spaced from adjacent optical fibers of the plurality of optical fibers at a precise pitch.