Optical Fiber Array Manufacturing Automation
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Solution Overview
Problem
The existing methods for manufacturing two-dimensional arrays of optical fibers are costly and prone to human errors due to manual operations, and the mechanical structure of the arrays is less than desirable due to limitations in support plate technology, requiring custom-made tools and expertise.
Innovation Solution
A mechanized technique using a handling tool with a clamp element and cutter to cleave and bond optical fibers within ferrules, allowing for precise positioning and adhesive application, enabling the formation of arrays with improved mechanical structure and reduced costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual operations are used for cleaving, installing, and bonding optical fibers, then flexibility and adaptability are maintained, but manufacturing precision deteriorates and human errors increase
Solution Approach 1:
The patent replaces manual mechanical operations with an automated handling tool that integrates multiple functions (holding, moving, clamping, positioning) into a single automated system. The handling tool uses mechanical clamping elements and positioning mechanisms to perform operations that were previously done manually, thereby improving precision while increasing automation.
Solution Approach 2:
The handling tool is designed as a multi-functional device that can perform multiple operations (holding the fiber, moving it to different positions, clamping it, and positioning it for bonding) without requiring separate tools for each operation. This universality streamlines the manufacturing process and improves consistency across all operations.
2Manufacturing precision
If custom-made tools and expertise are used for support plate technology, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the fiber assembly function from the complex support plate system and relocates it to a dedicated handling tool. This separation allows the support plate to be a simple, standardized component while the complex positioning and bonding operations are performed by the specialized handling tool, thereby reducing overall device complexity.
Solution Approach 2:
The patent employs a disposable or replaceable handling tool that can be easily manufactured and replaced, rather than investing in complex, custom-made support plate technology. This approach reduces the cost and complexity of the overall system while maintaining manufacturing precision through the specialized capabilities of the handling tool.
3Productivity
If manual bonding operations are performed, then adaptability to different fiber types is maintained, but productivity and consistency deteriorate
Solution Approach 1:
The patent replaces manual bonding operations with an automated handling tool that precisely positions and bonds fibers using controlled mechanical pressure and adhesive application. This automation ensures consistent bonding quality and increases productivity while eliminating the variability introduced by manual operations.
Solution Approach 2:
The handling tool is designed to automatically perform the bonding sequence without requiring manual intervention after the fiber is positioned. The tool self-regulates the bonding process through programmed movements and adhesive application, ensuring consistent results and high productivity.
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
The mechanized technique enhances precision and reduces costs by automating the process of cleaving, bonding, and positioning optical fibers within ferrules, resulting in a more reliable and efficient manufacturing method for optical fiber arrays.
Implementation Method 1
immerse the cleaved portion of the optical fiber in the adhesive reservoir; and insert the cleaved portion of the optical fiber with adhesive adhered thereto inside a ferrule
Data Source
AI summary
An apparatus for manufacturing an array of optical fiber using a handling tool, a clamp element, a cutter and an adhesive reservoir. The handling tool is capable of moving a portion of an optical fiber in a three-dimensional space and hold the portion of the optical fiber together with the clamp element to allow the cutter to produce a cleaved end in the optical fiber. The handling tool is further configured for immersing the cleaved end of the optical fiber in the adhesive reservoir and inserting the cleaved end of the optical fiber with adhesive adhered thereto inside a ferrule of an array of ferrules. A structure comprising the array of ferrules and a method of manufacturing an array of optical fibers are also disclosed.