Optical Coupler Ferrule Rotary Alignment
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Solution Overview
Problem
Existing optical path switching technologies face challenges in reducing power consumption and size while maintaining economical efficiency, particularly due to high energy requirements for motor-driven mechanisms and complex assembly processes.
Innovation Solution
The optical coupler and switch feature ferrules with convex spherical end faces, allowing for axial rotation without direct contact, which reduces power consumption and eliminates the need for reflection coatings, thereby simplifying the design and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a motor-driven mechanism is used for optical path switching, then the switching function is achieved, but the power consumption increases significantly
Solution Approach 1:
The patent replaces the motor-driven mechanical stage movement system with a rotary ferrule mechanism that rotates around a central axis. This substitution eliminates the need for high-torque motors and complex ball screw mechanisms, significantly reducing power consumption from several hundred milliwatts to much lower levels.
Solution Approach 2:
The patent employs a cylindrical ferrule structure that rotates around a central axis, creating a circular switching path. This rotary mechanism with spherical/curved geometry eliminates the need for linear motion conversion mechanisms like ball screws, reducing mechanical complexity and power requirements while maintaining precise optical alignment.
2Measurement precision
If optical axis alignment accuracy of 1 μm or less is required, then the switching precision is improved, but the driving time and power consumption increase
Solution Approach 1:
The rotary ferrule mechanism rotates around a central axis with precisely controlled radius, creating a circular path that maintains constant distance from the optical axis. This curved geometry with fixed radius enables rapid positioning with sub-micrometer accuracy without the need for slow, step-by-step linear movement, significantly reducing switching time.
3Ease of operation
If a robot arm scheme is used for connector insertion and extraction, then the switching function is achieved, but the power consumption increases to several tens of watts
Solution Approach 1:
The patent replaces the robot arm system with a simple rotary ferrule mechanism that achieves switching through rotation around a central axis. This eliminates the need for complex robotic manipulation, reducing power consumption from several tens of watts to much lower levels while maintaining ease of operation.
4Measurement precision
If a cylindrical ferrule is inserted into a sleeve for alignment, then the center axis alignment is achieved, but the frictional force requires much energy for rotation
Solution Approach 1:
The patent extracts the ferrule from the sleeve structure, eliminating the frictional contact between ferrule and sleeve that occurs in traditional insertion-based alignment systems. The ferrule rotates freely around the central axis without being constrained by a sleeve, removing the energy barrier caused by friction while maintaining precise center axis alignment through the rotary mechanism.
5Reliability
If a gap is formed between fiber end faces to prevent contact damage, then the fiber protection is improved, but reflection loss increases
Solution Approach 1:
The patent employs a rotary ferrule mechanism where the ferrule end face is positioned at a precise distance from the rotation axis, creating a curved switching path. This spherical geometry with controlled radius enables the ferrule to rotate and connect different fibers without the end faces coming into contact, protecting them from damage. The consistent radial distance maintains optimal optical coupling, minimizing reflection loss while preventing fiber contact.
Data Source
AI summary
An object of the present disclosure is to provide an optical coupler and an optical switch capable of achieving stable optical characteristics with low power consumption and more economical efficiency with respect to external factors.In order to achieve the above object,the optical coupler according to the present disclosure includesa first ferrule in which core centers of one or a plurality of single-core fibers are disposed on the same circumference from a center in a ferrule cross section, and which has an end face of a convex spherical shape in a direction of a ferrule center axis together with an end face of the single-core fiber;a second ferrule in which core centers of the plurality of single-core fibers are disposed on a circumference having the same diameter as the circumference on which the core centers of the single-core fibers are disposed in the first ferrule from the center in the ferrule cross section, and which has an end face of a convex spherical shape in the direction of the center axis of the ferrule together with the end face of the single-core fiber; anda cylindrical sleeve that has a hollow portion into which the first and second ferrules are inserted such that the ferrule center axes of the first ferrule and the second ferrule match, and the convex spherical end faces are opposite to each other, and in which a predetermined gap is provided between each outer diameter of the first ferrule and the second ferrule and an inner diameter of the hollow portion so that the first ferrule and the second ferrule are able to rotate.