High Density Optical Fiber Feedthrough Hermetic Sealing
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Solution Overview
Problem
Existing optical fiber feedthroughs face challenges in achieving high fiber density without increasing dimensions, leading to manufacturing difficulties, potential damage, and failed hermetic seals, which limits the quantity of optical fibers that can pass through a hermetic package.
Innovation Solution
A method and system for aligning and hermetically sealing optical ribbons in a specific orientation and sequence using alignment, stripping, and sealing apparatus, which maintains the orientation and removes slack to achieve a high fiber density within a hermetically sealed tube, allowing more optical fibers to pass through without increasing the feedthrough's dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the dimensions of the optical fiber feedthrough are increased to accommodate more optical fibers, then the quantity of optical fibers that can pass through increases, but the feedthrough size increases which is not desirable
Solution Approach 1:
The patent transitions from arranging optical fibers in a two-dimensional plane to a three-dimensional configuration within the feedthrough tube. By utilizing vertical stacking and radial arrangement of multiple fiber ribbons around a central axis, the design maximizes fiber density in three dimensions rather than simply expanding the horizontal cross-sectional area.
Solution Approach 2:
The patent implements a nested arrangement where multiple optical fiber ribbons are concentrically positioned around a central axis within the feedthrough tube. Each ribbon is arranged in a nested configuration, with fibers from different ribbons occupying different radial layers, similar to nested dolls, thereby maximizing space utilization without increasing external dimensions.
2Quantity of substance
If the fiber density is increased to pass more fibers through the same dimensions, then the quantity of optical fibers increases, but manufacturing difficulty increases and damage risk increases
Solution Approach 1:
The patent divides the optical fiber assembly into separate ribbons, each containing a manageable number of fibers. These ribbons are processed and positioned independently through the feedthrough, allowing for controlled manipulation of smaller fiber groups rather than handling a single large bundle, thereby reducing manufacturing complexity and damage risk.
Solution Approach 2:
The patent performs preliminary alignment and organization of optical fibers into ribbons before the hermetic sealing process. By pre-arranging fibers in their final configuration and securing them in place prior to sealing, the manufacturing process becomes more controlled and less prone to errors or damage during the sealing operation.
3Quantity of substance
If the fiber density is increased to pass more fibers through the same dimensions, then the quantity of optical fibers increases, but the risk of failed hermetic seals increases
Solution Approach 1:
The patent employs a flexible hermetic seal structure that can accommodate the three-dimensional arrangement of high-density fibers. The seal mechanism uses compliant materials and designs that can deform to fit around the bundled fiber ribbons, ensuring hermetic sealing without requiring rigid, precision-fitted components that would be difficult to implement with high fiber density.
4Manufacturing precision
If alignment apparatus is used to maintain orientation of optical ribbons, then misalignment is prevented, but device complexity increases
Solution Approach 1:
The patent incorporates self-aligning features directly into the feedthrough structure, such as positioning grooves, keyed interfaces, or geometric constraints that automatically guide the optical fiber ribbons into their correct orientations during assembly. This eliminates the need for complex external alignment apparatus, as the feedthrough itself provides the alignment function through its design.
Data Source
AI summary
A method may include aligning a portion of each of a plurality of optical ribbons in a particular orientation or sequence using a set of alignment apparatus. The method may include stripping the portion of each of the plurality of optical ribbons to expose a cladding of each fiber of the plurality of optical ribbons using a set of stripping apparatus. The method may include hermetically sealing a tube around the portion of each of the plurality of optical ribbons using a set of sealing apparatus. The method may produce a hermetic optical fiber feedthrough.