Optical Connector Recess Structure for Fiber-Waveguide Alignment
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Solution Overview
Problem
Existing techniques for optically coupling an optical fiber to an optical waveguide on a substrate face challenges in achieving precise alignment, which complicates the process.
Innovation Solution
The optical connector and waveguide component utilize projections and recesses formed with high positional accuracy using laser irradiation, allowing for easy alignment of optical fibers with the waveguide by fitting projections into recesses, and optionally using adhesive and latch mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional alignment techniques are used to couple optical fiber to optical waveguide, then the coupling can be achieved, but the alignment process becomes complicated and precise alignment is difficult
Solution Approach 1:
The patent introduces an intermediary alignment structure consisting of a block with openings and resin material that physically guides and positions the optical fiber relative to the optical waveguide. This intermediary mechanism simplifies the alignment process by providing a straightforward mechanical positioning system rather than requiring complex alignment procedures.
Solution Approach 2:
The alignment structure is prepared in advance with pre-formed openings and resin material that are designed to automatically position the optical fiber at the correct location. The fiber is inserted into the pre-prepared opening where the resin material holds it in the precise position needed for coupling with the waveguide, eliminating the need for complex real-time alignment adjustments.
2Reliability
If high alignment accuracy of 4 μm or less is achieved, then coupling efficiency is enhanced, but the alignment process becomes more difficult
Solution Approach 1:
The block with openings and resin material serves as a mechanical intermediary that automatically maintains the optical fiber at the precise position needed for 4 μm or better alignment accuracy. The resin material acts as an adhesive mediator that secures the fiber in the correct position, making high-precision alignment achievable through simple insertion rather than difficult adjustment procedures.
Solution Approach 2:
The alignment structure is designed to self-position the optical fiber into the correct alignment with the optical waveguide. The pre-formed opening and resin material create a self-aligning system where the fiber naturally settles into the precise position needed for high coupling efficiency, without requiring external alignment tools or complex adjustment mechanisms.
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
Facilitates precise alignment of optical waveguides and fibers with an accuracy of 4 μm or less, eliminating the need for optical axis adjustment and enhancing coupling efficiency.
Implementation Method 1
projections and recesses formed with high positional accuracy using laser irradiation
Data Source
AI summary
An optical connector includes a block, an optical fiber, and a resin material. A first opening and a second opening are formed in the block. The first opening and the second opening reach a first surface of the block. The optical fiber is in the first opening. The optical fiber has a first end face exposed on the first surface. The resin material is in the second opening. A recess is formed in the resin material. The recess has a wall face continuous with the first surface.