Optical Coupling System for Waveguide Alignment
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Solution Overview
Problem
The challenge in realizing integrated optical connections on printed circuit boards using optical waveguides lies in aligning and coupling the waveguide ends with optoelectronic components or external fiber cables, particularly due to the complexity of achieving precise alignment and connection.
Innovation Solution
An optical coupling system where the end faces of polymer and glass fiber waveguides are aligned by forming a cladding together, with guide devices on the ferrule and printed circuit board ensuring axial alignment, and stripping the sheaths to expose contact surfaces for precise positioning, allowing for easy and accurate coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional alignment methods are used for coupling optical waveguides, then the coupling process becomes complex and difficult to implement, but achieving precise alignment is essential for efficient optical connections
Solution Approach 1:
A ferrule is introduced as an intermediary component that receives both the polymer optical waveguide and the glass fiber, providing a common reference frame for alignment. The ferrule's internal geometry and external guide devices mediate the coupling process, transforming a complex direct alignment problem into a simpler insertion-based assembly.
Solution Approach 2:
The ferrule is pre-configured with guide devices and dimensional features that establish alignment references before the actual coupling occurs. The axial portion and lateral guide structures are prepared in advance, so that when the waveguides are inserted, alignment is automatically achieved without requiring complex adjustment mechanisms during assembly.
2Ease of operation
If the waveguide ends are directly connected without additional structures, then the connection structure is simple, but alignment in multiple directions cannot be achieved
Solution Approach 1:
The ferrule incorporates asymmetric dimensional features, including a specific axial portion length and non-circular cross-sectional dimensions (e.g., rectangular or square profile), which create unique mechanical references for alignment. This asymmetry ensures that the waveguides can only be inserted in the correct orientation, automatically achieving alignment in lateral directions without requiring complex adjustment mechanisms.
Solution Approach 2:
The alignment problem, which would otherwise require complex mechanisms in lateral directions, is solved by introducing a new dimensional approach: the ferrule's external dimensions and guide devices provide alignment references that extend beyond the simple end-face contact, utilizing the ferrule's overall geometry to constrain and align the waveguides in multiple directions simultaneously.
3Manufacturing precision
If the cores are made flush in the axial direction, then the coupling location achieves precise positioning, but the sheath alignment becomes more challenging
Solution Approach 1:
The ferrule creates an equipotential alignment environment by providing a common reference frame for both cores and sheaths. The internal geometry of the ferrule ensures that when the waveguides are inserted to the same depth (defined by the axial portion), both the cores and sheaths are automatically aligned relative to each other, eliminating the need for separate alignment procedures.
Solution Approach 2:
The ferrule serves multiple functions simultaneously: it holds both the polymer waveguide and glass fiber, provides alignment references for both cores and sheaths, and ensures proper positioning in a single component. This multi-functionality simplifies the manufacturing process by consolidating what would otherwise require multiple separate alignment and fixation operations.
Data Source
AI summary
An optical coupling system for coupling a first optical waveguide having a first core surrounded by a first sheath to a second optical waveguide having a second core surrounded by a second sheath. An end face of the first core of the first optical waveguide abuts an end face of the second core of the second optical waveguide at a coupling location and the second core is flush with the first core in the axial direction, wherein, in the region of the coupling location, over at least part of a predetermined axial portion, both the second sheath of the second optical waveguide and the first sheath of the first optical waveguide together form a cladding of the optical waveguide in the predetermined portion.