Monolithic Optical Fiber Coupler with Wedge and Plane Windows
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Solution Overview
Problem
Conventional optical fiber couplers are expensive due to precision adjustment tooling and have complex mechanical parts, making alignment difficult and sensitive to shock and vibration, requiring manual adjustment and locking mechanisms that can cause misalignment.
Innovation Solution
A monolithic optical fiber coupler design with a base plate incorporating a wedge window pair and a plane window, allowing for adjustment and alignment of light beams in a compact, integrated system with fewer parts, reducing the need for precision adjustment tooling and enhancing stability against shock and vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional optical fiber couplers use precision adjustment tooling and mechanical locking mechanisms, then alignment accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent integrates the base plate, wedge window pair, and plane window into a single monolithic structure. The base plate serves multiple functions: providing structural support, enabling beam adjustment through integrated wedge windows, and facilitating alignment through integrated plane windows. This merging eliminates separate mechanical adjustment components and locking mechanisms, reducing device complexity while maintaining alignment accuracy through the inherent stability of the monolithic design.
2Adaptability or versatility
If conventional optical fiber couplers use multiple mechanical parts and interdependent alignment axes, then adjustability is improved, but ease of operation deteriorates due to difficult alignment
Solution Approach 1:
The monolithic base plate is functionally segmented into distinct regions: a wedge window pair for beam tilt adjustment, a plane window for beam positioning, and mounting areas for optical components. Each segment performs a specific alignment function independently, allowing straightforward sequential adjustment without the complex interdependencies found in conventional multi-component systems. The segmentation is achieved through functional integration rather than physical separation.
3Reliability
If conventional optical fiber couplers use mechanical locking mechanisms, then stability against shock and vibration is improved, but alignment precision deteriorates due to locking-induced misalignment
Solution Approach 1:
The patent replaces mechanical locking mechanisms with a monolithic structural design. The base plate, wedge windows, and plane windows are integrated into a single rigid structure that inherently resists shock and vibration without requiring locking screws or mechanical fasteners. The alignment is maintained through the rigid monolithic construction rather than mechanical locking, eliminating the problem of locking-induced misalignment while preserving vibration resistance.
4Manufacturing precision
If conventional optical fiber couplers use precision adjustment tooling, then manufacturing precision is improved, but ease of manufacture deteriorates due to expensive tooling requirements
Solution Approach 1:
The base plate, wedge window pair, and plane window are manufactured as a single monolithic component using conventional machining techniques. This integration eliminates the need for precision adjustment tooling that would be required to assemble and align multiple separate components. The monolithic design allows standard manufacturing processes to achieve the required precision, significantly reducing tooling costs while maintaining alignment accuracy.
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 reduces costs, simplifies alignment, and increases stability by bonding optical components to a monolithic base plate, ensuring efficient light coupling and resistance to mechanical instability, while eliminating the need for precision adjustment tooling and sensitive kinematic mounts.
Implementation Method 1
The wedge window pair is mounted to the base plate, and is configured to adjust the light beam to be parallel to an optical axis of the fiber collimator
Implementation Method 2
The plane window is mounted to the base plate between the wedge window pair and the fiber collimator. The plane window is configured to align the parallel direction of the light beam with the optical axis of the fiber collimator
Implementation Method 3
The fiber collimator is mounted to a base plate and includes a collimator lens, an end of the optical fiber being positioned at a focal point of the collimator lens
Data Source
AI summary
A coupling device includes a fiber collimator, a wedge window pair and a plane window for coupling a light beam provided by a beam source to optical fiber. The fiber collimator is mounted to a base plate and includes a collimator lens, an end of the optical fiber being positioned at a focal point of the collimator lens. The wedge window pair is mounted to the base plate, and is configured to adjust the light beam to be parallel to an optical axis of the fiber collimator. The plane window is mounted to the base plate between the wedge window pair and the fiber collimator. The plane window is configured to align the parallel direction of the light beam with the optical axis of the fiber collimator.