Optical Fiber Connector With Self-Aligning Cap
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Solution Overview
Problem
Existing optical connectors for high-density optical fiber arrays and silicon photonic chips lack precise alignment and manufacturing simplicity, leading to increased power consumption and complexity in data communication systems.
Innovation Solution
The optical connector features a frame with a longitudinally extending trench and a positioning assembly that includes a fiber support member with longitudinal grooves and a cap with an alignment surface. The cap is wider than the fiber support member, allowing its free portions to rest on the frame walls, ensuring precise vertical alignment of the optical fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional optical connectors are used for high-density optical fiber arrays, then manufacturing complexity and device complexity increase, but alignment precision and manufacturing simplicity are insufficient
Solution Approach 1:
The connector is divided into distinct functional modules: a positioning assembly with V-grooves for fiber alignment, a cap with alignment surface, and a frame with trench. Each module performs a specific function, allowing independent optimization and simplifying manufacturing while maintaining high alignment precision through the segmented structural design
Solution Approach 2:
The positioning assembly uses self-aligning V-grooves that automatically guide optical fibers into correct positions during insertion. The cap's alignment surface with free portions resting on frame walls provides self-adjusting vertical alignment, eliminating the need for complex external alignment mechanisms and reducing device complexity
2Manufacturing precision
If alignment surfaces are polished to sub-micron flatness, then manufacturing precision improves, but manufacturing complexity increases
Solution Approach 1:
Sub-micron polishing is applied only to critical alignment surfaces (the cap's alignment surface and frame wall contact areas) rather than entire components. This localized high-precision processing achieves necessary alignment accuracy while minimizing overall manufacturing complexity and cost
Solution Approach 2:
Alignment surfaces are polished to sub-micron flatness during the manufacturing process before final assembly. This preliminary precision preparation ensures that when components are assembled, the alignment is already optimized, eliminating the need for complex post-assembly adjustment mechanisms
Data Source
AI summary
An optical connector includes a fiber positioning assembly and a frame having two walls for supporting the fiber positioning assembly in a controlled vertical alignment relative to the frame. The fiber positioning assembly includes an optical fiber array disposed at a top surface of a support block for positioning between the walls, and a cap covering top portions of the optical fibers projecting from the block. The cap has a flat alignment surface resting upon the fiber top portions and extending laterally beyond the support block such that when the block is disposed between the walls, free portions of the alignment surface rest upon the walls to control the vertical alignment of the array. A single rail affixed to a bottom shelf of the frame, and a correspondingly dimensioned rectangular notch at the bottom of the support block, control the horizontal alignment of the array.