Nested Capillary Structure for Stable Optical Fiber Polishing
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Solution Overview
Problem
Connecting an optical fiber bundle structure to a multicore fiber at low loss with improved reliability is challenging due to the difficulty in stabilizing the polishing of small-diameter optical fibers without chipping, especially when the capillary and fibers have thin walls, which can lead to unreliable connections and increased costs.
Innovation Solution
A method involving the use of a large-diameter capillary fixed around a small-diameter capillary to facilitate stable end-face polishing, followed by removal, ensuring the small-diameter capillary's outer diameter matches the multicore fiber's, using thermoplastic resin without coupling agents for easy detachment and high mold-releasability, and optionally forming a double-layer capillary structure or creating slits for easier removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a small-diameter capillary with thin wall thickness is used to match the multicore fiber outer diameter, then the connection structure achieves high-density packaging and reduced weight, but chipping occurs during end-face polishing and manufacturing stability deteriorates
Solution Approach 1:
A large-diameter capillary is inserted into the small-diameter capillary to form a nested structure. The large-diameter capillary provides mechanical support and stability during polishing, while the small-diameter capillary maintains the required outer diameter match with the multicore fiber. After polishing, the large-diameter capillary is removed, leaving the lightweight small-diameter capillary in place.
2Volume of moving object
If a small-diameter capillary with thin wall thickness is used to match the multicore fiber outer diameter, then the connection structure achieves high-density packaging, but the capillary and optical fibers are damaged during polishing
Solution Approach 1:
The large-diameter capillary is inserted into the small-diameter capillary before polishing to provide protective support. This cushioning structure prevents the thin-walled small-diameter capillary and optical fibers from breaking during the polishing process, while not interfering with the final compact dimensions.
3Volume of moving object
If the outer diameter of the optical fiber bundle structure is reduced to match the multicore fiber, then high-density packaging is achieved, but the wall thickness of the capillary becomes too thin for stable manufacturing
Solution Approach 1:
The nested capillary structure allows the small-diameter capillary to maintain its compact outer diameter for high-density packaging while the inserted large-diameter capillary provides the necessary wall thickness for stable manufacturing and handling during the polishing process.
Data Source
AI summary
First, small-diameter portions of a plurality of optical fibers are inserted into a small-diameter capillary. Then, in a state in which the optical fibers are inserted into the small-diameter capillary until end faces of the optical fibers protrude slightly from an end face of the small-diameter capillary, the optical fibers and the small-diameter capillary are fixed together by using an adhesive. Next, a large-diameter capillary is fixed on an outer periphery of the small-diameter capillary. Then, end faces of the large-diameter capillary, the small-diameter capillary, and the optical fibers (the small-diameter portions) are polished collectively to mirror-finish the end faces of the optical fibers. Next, the large-diameter capillary is removed from the small-diameter capillary. In this way, an optical fiber bundle structure can be obtained.