Optical Fiber Array Connector With Square-Lattice Alignment
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Solution Overview
Problem
Existing optical fiber array connectors face challenges in achieving high-density data transmission with stable fiber alignment and efficient coupling, particularly in passive, pluggable interconnects for optical fiber arrays and photonic chips, due to insufficient mechanical stability and alignment precision.
Innovation Solution
The use of a fiber array unit with opposing grooved plates holding optical fibers in a square lattice configuration, where the groove pitch is approximately √2 times the fiber diameter, and v-grooves with an apex angle less than 90 degrees, providing enhanced lateral stability and alignment precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If optical fibers are densely packed in traditional connector configurations, then fiber array density increases, but mechanical stability and alignment precision deteriorate
Solution Approach 1:
The patent transitions from traditional 2D planar fiber arrays to a 3D spatial configuration where fibers are arranged in multiple layers with vertical stacking. The grooved plates are positioned at different heights (z-axis) to hold fiber arrays in separate planes, enabling high-density packing while maintaining mechanical stability through three-dimensional spatial distribution rather than simple lateral compression
Solution Approach 2:
The patent implements a nested structure where multiple fiber arrays are stacked vertically within a single connector housing. Each grooved plate holds a layer of fibers, and these plates are nested one above another along the optical axis. This nesting approach allows multiple fiber bundles to occupy the same lateral footprint while maintaining independent mechanical support for each layer, thereby increasing density without sacrificing alignment precision
2Quantity of substance
If groove pitch is reduced to increase fiber density, then fiber array density improves, but manufacturing precision and alignment accuracy worsen
Solution Approach 1:
The patent divides the fiber array into multiple separate groups, with each group held on an independent grooved plate. Instead of attempting to pack all fibers tightly in a single plane with reduced pitch, the system segments fibers across multiple plates positioned at different vertical levels. Each plate maintains its own groove pitch optimized for manufacturing, while the overall density increases through vertical stacking of these segmented arrays
Solution Approach 2:
The patent resolves the pitch-density contradiction by moving the density increase from the lateral dimension (x-y plane) to the vertical dimension (z-axis). The groove pitch within each plate remains sufficient for manufacturing precision, while the overall fiber array density improves through vertical stacking of multiple plates with spaced-apart grooves, effectively trading lateral compactness for vertical layering
3Reliability
If v-groove apex angle is reduced to enhance lateral stability, then mechanical stability improves, but device complexity increases
Solution Approach 1:
The patent optimizes the v-groove apex angle parameter to a specific range (60-90 degrees) that balances lateral stability with manufacturing simplicity. This parameter optimization ensures that the grooves provide sufficient mechanical constraint for fiber alignment while avoiding excessively complex geometries. The chosen angle range creates stable fiber seating without requiring precision machining beyond standard capabilities, thus improving stability without proportionally increasing device complexity
Data Source
AI summary
An optical fiber array unit of an optical connector includes an opposing pair of grooved plates holding at least three rows of optical fibers between them, with at least some of the optical fibers in each of the at least three rows touching two optical fibers of an adjacent one of the at least three rows. Each grooved plate of the opposing pair has an array of parallel fiber-holding grooves. In some implementations, a groove pitch of the array may be such that the cores of the optical fibers are located at nodes of a square lattice.