Optical Connector Self-Alignment Structure for Single-Mode Waveguides
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Solution Overview
Problem
Conventional optical connectors require high-precision work for accurate position alignment, which is complex and challenging, especially for single mode optical waveguides.
Innovation Solution
An optical connector design featuring a waveguide member with specific clad and contact layers forming obtuse angles, fixed to a holding member with guided alignment through concave portions and adhesive fixation, allowing for high alignment accuracy using excimer laser processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional optical connector design is used, then alignment accuracy can be achieved, but the manufacturing process becomes complex and difficult
Solution Approach 1:
The waveguide member is divided into multiple functional layers (core layer, first clad layer, second clad layer, first contact layer, second contact layer) with distinct roles. The core layer guides optical signals while contact layers provide alignment references. This segmentation allows each layer to be optimized independently and simplifies the overall manufacturing process.
Solution Approach 2:
The first contact layer and second contact layer are formed to protrude from the waveguide member before final assembly. These contact layers serve as pre-formed alignment references that guide the positioning of the holding member, eliminating the need for complex post-assembly adjustments and high-magnification optical instruments.
2Measurement precision
If high-magnification optical instruments are used for alignment, then alignment accuracy is improved, but the manufacturing process becomes more complicated
Solution Approach 1:
The contact layers are designed to automatically guide alignment through their geometric configuration. The first contact layer with its second surface and third surface, and the second contact layer with its fourth surface and fifth surface, create self-aligning features that naturally position the waveguide member relative to the holding member without requiring external measurement instruments.
Solution Approach 2:
The patent replaces optical measurement systems (microscopes, alignment tools) with a mechanical self-alignment system based on geometric contact surfaces. The obtuse angles formed by the contact layers create mechanical constraints that ensure precise positioning through physical contact rather than optical measurement.
3Reliability
If single mode optical waveguide is manufactured, then transmission quality is improved, but alignment work becomes more complicated
Solution Approach 1:
The contact layers are positioned at specific locations on the waveguide member to provide localized alignment references. The first contact layer and second contact layer are strategically placed to guide positioning in different directions, ensuring that the critical alignment areas receive the necessary geometric constraints while the rest of the waveguide maintains its single-mode transmission properties.
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
Achieves high alignment accuracy of 2 μm or less, simplifying the manufacturing process and ensuring precise alignment suitable for single mode transmission.
Implementation Method 1
forming a sixth surface, on a side of the first contact layer viewed from the second clad layer, continuous with the first surface, and forming an obtuse angle with the first surface, and a seventh surface, on a side of the second contact layer when viewed from the second clad layer, continuous with the first surface, and forming an obtuse angle with the first surface
Implementation Method 2
a holding member to which the waveguide member is fixed
Data Source
AI summary
An optical connector includes a holding member to which a waveguide member is fixed. The waveguide member includes a first clad layer having a longitudinal direction and a first surface, a core layer provided on the first surface, a second clad layer provided on the first surface and covering the core layer, and first and second contact layers provided on the first surface, sandwiching the core layer in a cross sectional view perpendicular to the longitudinal direction and exposed from the second clad layer. The first contact layer includes a second surface making contact with the first surface, and a third surface opposite to the second surface, and the second contact layer includes a fourth surface making contact with the first surface, and a fifth surface opposite to the second surface. The first clad layer includes sixth and seventh surfaces forming obtuse angles with the first surface.