Optical Waveguide Component With Projection-Recess Alignment

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Solution Overview

Problem

Existing optical waveguide component manufacturing processes are time-consuming due to the need for precise optical axis alignment and adhesive curing during polymer waveguide and optical fiber coupling.

Innovation Solution

The optical waveguide component design incorporates projections on a substrate that fit into recesses in a glass block, allowing passive alignment and eliminating the need for separate adhesives, with the use of a multi-layer cladding structure for enhanced bonding and positional accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If optical axis alignment and adhesive application are performed during manufacturing, then optical coupling between polymer waveguide and optical fiber is achieved, but manufacturing time increases

Engineering Contradiction:

Improveoptical coupling precisionVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The projection and recess structure enables passive alignment where the components self-align through mechanical interference fit, eliminating the need for active optical axis alignment operations. The projection on the substrate fits into the recess of the glass block, automatically positioning the optical waveguide and optical fiber in correct alignment.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The projection and recess are pre-formed on the substrate and glass block respectively, before the bonding process. This preliminary structural preparation enables automatic alignment when components are assembled, eliminating the need for time-consuming alignment operations during manufacturing.

Inventive Principle:

Principle #10Preliminary action

2Strength

If adhesive application and curing processes are used, then bonding between components is achieved, but manufacturing complexity and time increase

Engineering Contradiction:

Improvebonding strengthVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The invention extracts and eliminates the adhesive application and curing processes from the manufacturing workflow. By using direct mechanical interference fit between the projection and recess, the complex multi-step adhesive process is replaced with a simple assembly operation.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The chemical bonding process (adhesive application and curing) is replaced with a mechanical bonding system (projection fitting into recess). This substitution eliminates the need for chemical materials and curing equipment, simplifying the manufacturing process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20250306286A1Optical waveguide component and method of making optical waveguide component

Publication Date: 2025.10.02 SHINKO ELECTRIC IND CO LTD

AI summary

An optical waveguide component includes a substrate having a first surface, an optical waveguide disposed on the first surface, a projection formed on the first surface, a glass block including an optical fiber and including a recess into which the projection fits, wherein the optical waveguide and the optical fiber are optically coupled.