Optical Fiber Array Resin Support UV Curing
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Solution Overview
Problem
Existing optical fiber arrays face challenges with low mass-productivity and high manufacturing costs due to the use of glass materials, which also have low shape-flexibility and are prone to damage from impact, and the process of arranging optical fibers in a mold with UV curable resin results in low productivity.
Innovation Solution
An optical fiber array is designed using a support member made of a mixture of thermoplastic or thermosetting resin with a filler, ensuring high UV light transmittance for curing while restricting visible light transmittance to facilitate accurate positioning and measurement, and using a UV curable resin for easy and efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If glass material is used for optical fiber array, then alignment precision is improved, but mass-productivity deteriorates due to long grinding lead time and manufacturing cost increases due to grinding tool wear
Solution Approach 1:
The invention changes the material parameter from glass to resin, which fundamentally alters the manufacturing process from precision grinding to mold injection. This parameter change enables mass production while maintaining alignment precision through mold-based positioning structures.
Solution Approach 2:
The invention replaces the mechanical grinding system with a mold-based injection system. Instead of using grinding tools to achieve precision alignment, the patent uses pre-formed positioning structures within injection molds to automatically align optical fibers during the molding process, eliminating the need for subsequent grinding operations.
2Manufacturing precision
If glass material is used for optical fiber array, then alignment precision is improved, but device reliability deteriorates due to low shape-flexibility and susceptibility to impact damage
Solution Approach 1:
The invention changes the material parameter from glass to resin, which fundamentally alters the mechanical properties. Resin provides flexibility and impact resistance while maintaining alignment precision through mold-based positioning structures, thereby improving device reliability without sacrificing manufacturing precision.
3Ease of manufacture
If UV curable resin is used to form optical fiber array in mold, then ease of manufacture is improved, but mass-productivity deteriorates due to lengthy process steps
Solution Approach 1:
The invention merges multiple separate process steps into a single integrated injection molding operation. Instead of separately arranging fibers, pouring resin, curing, and removing molds in sequence, the patent integrates fiber placement and resin injection into one simultaneous process, dramatically improving productivity while maintaining ease of manufacture.
Solution Approach 2:
The invention performs preliminary action by pre-forming positioning structures and channels within the injection mold before the actual molding process. This allows optical fibers to be automatically positioned and secured during the injection process itself, eliminating subsequent assembly steps and improving overall manufacturing efficiency.
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 design allows for the rapid and cost-effective fabrication of optical fiber arrays with improved mass-productivity, ensuring sufficient UV light reaches the adhesive for secure fixation while maintaining temperature stability and accurate size measurement.
Implementation Method 1
a UV curable adhesive agent may be used for fixation. Since the UV curable adhesive agent is cured by being exposed in UV light
Data Source
AI summary
An optical fiber array according to one embodiment includes: an optical fiber; and a support member that supports the optical fiber. The support member comprises a mixture material of a base material and a solid material made of a material different from the base material, in which the base material contains at least either of thermoplastic resin or thermosetting resin, a light transmittance for at least one wavelength within a UV light wavelength range greater than or equal to 300 nm and less than or equal to 450 nm with respect to the support member having a thickness of 3 mm is 30% or greater, and an average light transmittance for a wavelength within a visible light wavelength range greater than or equal to 380 nm and less than or equal to 780 nm with respect to the support member having a thickness of 3 mm is 70% or less.