Multi-Fiber Connector Rotation Alignment via Flat Surface Shaping
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Solution Overview
Problem
Existing methods for rotation alignment of non-axisymmetric multi-core fibers in multi-fiber connectors face challenges with manufacturing accuracy due to incompatibility with general positioning components, such as ferrules, and interference issues with rotation preventing members.
Innovation Solution
A manufacturing method involving shaping the end portion of each optical fiber to form a flat surface, aligning it with a reference surface on a jig, fixing it to a positioning component, and cutting and grinding to achieve precise rotation alignment, allowing for the use of standard positioning components and maintaining high accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rotation preventing members are used to achieve rotation alignment of non-axisymmetric multi-core fibers, then alignment accuracy is improved, but device complexity and interference issues increase
Solution Approach 1:
The invention utilizes the inherent non-axisymmetric shape of multi-core fibers by forming a flat surface on the fiber end that corresponds to the asymmetric core arrangement. This flat surface serves as a natural alignment feature that interfaces with the positioning component, eliminating the need for separate rotation preventing members. The asymmetric geometry of the fiber itself becomes the alignment mechanism, resolving the contradiction between alignment accuracy and device complexity.
Solution Approach 2:
The invention extracts the alignment function from separate rotation preventing members and integrates it directly into the fiber structure itself through the formation of a flat surface on the fiber end. By taking out the need for additional alignment components and embedding the alignment feature in the fiber, the solution reduces device complexity while maintaining alignment accuracy.
2Ease of manufacture
If general positioning components like ferrules are used, then ease of manufacture and cost are improved, but manufacturing accuracy deteriorates due to incompatibility with non-axisymmetric fibers
Solution Approach 1:
The invention applies local quality by modifying only the end portion of the optical fiber where a flat surface is formed, while the rest of the fiber structure remains unchanged. This localized modification allows general positioning components to be used without requiring changes to the entire fiber or positioning component design, thereby maintaining ease of manufacture while achieving the necessary rotation alignment precision through the flat surface feature.
Solution Approach 2:
The invention performs preliminary action by pre-forming the flat surface on the optical fiber end before insertion into the positioning component. This preliminary shaping of the fiber end ensures that when the fiber is inserted into a general positioning component, the flat surface automatically provides the correct rotational orientation, achieving high alignment precision without requiring specialized positioning components.
3Manufacturing precision
If complex positioning components are designed to accommodate non-axisymmetric fibers, then rotation alignment accuracy is improved, but manufacturing cost and complexity increase
Solution Approach 1:
Instead of designing complex positioning components to accommodate the non-axisymmetric shape of multi-core fibers, the invention inverts the approach by modifying the fiber itself to have a flat surface that can be accommodated by simple, general positioning components. This inversion transfers the complexity from the positioning component to the fiber preparation process, thereby reducing device complexity while maintaining alignment precision.
Data Source
AI summary
A manufacturing method for manufacturing a multi-fiber connector, including: shaping a part of each of a plurality of optical fibers such that a part of an outer peripheral surface of a glass fiber including one end portion becomes a flat surface; arranging each of the plurality of optical fibers in a positioning component such that the entire flat surface protrudes from the positioning component; rotationally aligning each of the plurality of optical fibers such that the flat surface comes into contact with a reference surface of a jig; fixing each of the plurality of optical fibers to the positioning component; and cutting and removing a part of the glass fiber which protrudes from the positioning component and includes the flat surface and grinding a cut surface of each of the plurality of optical fibers which is exposed from the positioning component.