Optical Assembly Fiber Alignment via Dual Frame Elements
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Solution Overview
Problem
Existing optical fiber assemblies lack precise alignment for multiple pairs of fibers to direct light effectively through a single lens assembly to multiple sensors, such as photodiode arrays, leading to misalignment issues.
Innovation Solution
The use of first and second frame elements with opposing surfaces to positionally align and orient the exposed ends of multiple pairs of optical fibers, ensuring that centers of corresponding pairs are diametrically opposed about a common center point, allowing for efficient light transmission and reflection between input and output fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple pairs of optical fibers are inserted into a housing with grooves or apertures, then the fibers are grouped together in an assembly, but dimensional tolerances accumulate to cause misalignment of the optical fibers
Solution Approach 1:
A alignment aid component is introduced as an intermediary element between the housing and the optical fibers. This alignment aid includes positioning features such as V-grooves or aligned apertures that serve as mediators to guide and position multiple pairs of optical fibers relative to each other, ensuring precise alignment without requiring the housing itself to provide perfect dimensional tolerances.
Solution Approach 2:
The alignment function is segmented from the housing structure. Instead of relying on the housing's dimensional tolerances to align all fibers simultaneously, the alignment aid is separated as a dedicated component that provides the positioning function. This segmentation allows the housing to be manufactured with standard tolerances while the alignment aid ensures precise fiber positioning through its own specialized positioning features.
2Manufacturing precision
If fibers are tightly or loosely inserted into a one-piece housing aperture, then the housing provides a fixed structure, but the dimensional tolerances of the walls determine fiber alignment and may result in misalignment
Solution Approach 1:
The alignment aid acts as an intermediary that mediates between the housing structure and the optical fibers. It provides the precise positioning function that cannot be reliably achieved through housing wall tolerances alone, while the housing can be manufactured with standard tolerances. The alignment aid's positioning features (V-grooves, aligned apertures) serve as the critical alignment reference.
3Productivity
If one optical fiber transmits light through a lens assembly to a sensor, then light transmission is achieved, but multiple pairs of fibers cannot be adequately aligned to direct light through a single lens assembly to multiple sensors
Solution Approach 1:
The alignment aid is designed with universal positioning features that can simultaneously align multiple pairs of optical fibers. The V-grooves or aligned apertures in the alignment aid provide a common reference framework that works for all fiber pairs, enabling the system to handle multiple fibers with the same alignment mechanism that would be too complex to design individually for each fiber pair.
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
This configuration ensures that a significant portion of transmitted light is reflected and received by the corresponding output fibers, improving the accuracy and efficiency of light transmission and reception, even when using multiple sensors, by maintaining precise alignment and orientation of optical fibers.
Implementation Method 1
Optical fibers are often grouped together into assemblies in which the fibers extend generally parallel to each other
Implementation Method 2
The corresponding optical fiber of the pair receives a part of the light that is reflected back from the lens assembly
Data Source
AI summary
An optical device has a first frame element and second frame element. At least portions of a plurality of optical fiber pairs of an array each including an exposed end are arranged between the two frame elements. A region is defined between opposing surfaces of the two frame elements to hold the optical fibers. When holding the fibers, the two frame elements cooperate to positionally align and orient the exposed ends of each of the optical fibers for at least one of transmitting and receiving light. An optical system with the device includes a TAP photodiode array such that a portion of light is transmitted from at least a pair of input optical fibers to a corresponding pair of photodiodes of the array, and a portion of light is reflected back from an optical filter to output optical fibers corresponding to the input optical fibers.