Monolithic Fabry-Perot Optical Sensor for Robust Miniaturization
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Solution Overview
Problem
Existing miniature optical fiber pressure sensors are either too large or have complex manufacturing procedures, and often suffer from fragility and structural stresses due to separate components joined through splicing or bonding.
Innovation Solution
A single-piece optical element with a cavity and diaphragm is permanently joined to the end of a lead optical fiber, forming a Fabry-Perot resonator where the diaphragm is flexible, reducing manufacturing stresses and allowing for a miniature sensor with reduced size and increased robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate components (spacer and diaphragm) are joined through splicing or bonding to form the sensor, then the sensor can be assembled, but the sensor becomes fragile and suffers from structural stresses
Solution Approach 1:
The patent merges the spacer and diaphragm into a single monolithic component that is permanently joined to the optical fiber as one integrated structure. This eliminates the need for separate splicing or bonding operations, thereby removing the structural weaknesses and stresses introduced by joining multiple components, while simultaneously reducing device complexity by consolidating multiple parts into one unified element
2Manufacturing precision
If conventional joining methods (splicing or bonding) are used to assemble sensor components, then the sensor can be manufactured, but manufacturing stresses are introduced affecting sensor stability
Solution Approach 1:
The invention combines multiple sensor components into a single monolithic structure that is permanently joined to the optical fiber in one manufacturing step. This approach eliminates the manufacturing stresses and precision issues associated with separate splicing or bonding operations, while actually simplifying the manufacturing process by reducing the number of steps and potential sources of error
3Volume of moving object
If the sensor diameter is made equal to the optical fiber diameter for miniaturization, then the sensor size is reduced, but the manufacturing procedure becomes complicated requiring special tools and materials
Solution Approach 1:
The patent integrates the spacer and diaphragm into a single monolithic component that is permanently joined to the optical fiber. This merging of components simplifies the manufacturing process by eliminating the need for complex assembly operations, special tools, and materials that would otherwise be required to join separate components, while maintaining the miniaturized sensor diameter equal to the optical fiber diameter
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 results in a miniature optical sensor that is more durable, less prone to drift, and simpler to manufacture, with improved sensitivity and stability, suitable for applications requiring small size, high frequency response, and resistance to electromagnetic interference.
Implementation Method 1
shaping the second end of the optical element to define a diaphragm extending across the cavity, the diaphragm being flexible in response to the parameter
Implementation Method 2
The flat cleaved lead fiber end and the diaphragm form two reflective surfaces that define a Fabry-Perot interferometer. The optical signal from the lead optical fiber is split into two paths which mutually interfere.
Implementation Method 3
The optical signal from the lead optical fiber is split into two paths which mutually interfere. The sum of their interference is function of the distance between the fiber end and the diaphragm position
Data Source
Figure 1
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Figure 6A~6H
AI summary
An optical sensor and a method of manufacturing such as sensor are provided. The sensor includes a lead optical fiber with a single piece optical element joined permanently joined to its forward end. The optical element defines a spacer with a cavity therein at one end, and a diaphragm at the opposite end. The diaphragm is flexible in response to a parameter and the sensor defines a sensing Fabry-Perot resonator.