Multilayer Optical Waveguide Connector Alignment
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Solution Overview
Problem
Existing multi-core optical connectors face challenges in maintaining precise alignment and efficient resin injection in multilayer structures without a dummy-core structure, leading to connection loss and difficulties in providing space for UV-cured resin injection along the multilayered direction.
Innovation Solution
A ferrule with a containing unit and grooves along the multilayered direction allows for the injection of resin or adhesive between optical waveguides, ensuring they reach each layer, facilitating an easy-to-make multilayer structure using a simple flexi-waveguide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dummy-core structure and waveguide tray are used for precise alignment, then connection loss is reduced, but device complexity increases
Solution Approach 1:
The invention extracts and eliminates the dummy-core structure from the connector design. Instead of using a complex dummy-core and tray assembly, the patent employs a simplified ferrule with integrated positioning holes that directly guide the optical waveguides, achieving precise alignment without the additional dummy components.
Solution Approach 2:
The ferrule in the invention serves multiple functions simultaneously: it provides mechanical support, contains positioning holes for alignment, and guides the optical waveguides. This multi-functional design replaces the separate dummy-core and tray components, reducing overall device complexity while maintaining alignment precision.
2Ease of manufacture
If optical waveguides are stacked without resin injection space, then manufacturing is simplified, but alignment precision deteriorates
Solution Approach 1:
The invention incorporates resin injection spaces and grooves into the ferrule design before the stacking process. This preliminary preparation ensures that UV-cured resin can be properly injected to secure the optical waveguides in precise positions, maintaining alignment precision while keeping the manufacturing process straightforward.
3Device complexity
If UV-cured resin is not injected along the multilayered direction, then manufacturing process is simplified, but assembly stability deteriorates
Solution Approach 1:
The invention adds vertical grooves along the multilayered direction to enable UV-cured resin injection from the side rather than from above. This dimensional change in the injection approach allows resin to reach all stacked optical waveguides effectively, ensuring assembly stability while keeping the injection process simple.
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 reduces connection loss and enables high-precision alignment and efficient resin distribution, achieving effective assembly and securing of optical waveguides with low viscosity UV adhesive, thereby enhancing the multilayer structure's stability and performance.
Implementation Method 1
irradiating the MT connector with UV light after injection of resin or adhesive
Data Source
AI summary
Methods for fabricating connectors for multilayered optical waveguides, as well as apparatuses for multilayered optical waveguides that embody ferrules and connectors. The method of fabricating a connector includes the steps of: stacking in a containing unit of a ferrule, a plurality of optical waveguides that are each preliminarily formed in the shape of layers; and injecting resin or adhesive through a space lying between the plurality of optical waveguides and the containing unit of the ferrule, with the plurality of optical waveguides contained in a stacked manner so that resin or adhesive reaches each of the plurality of optical waveguides.