Self-Centering Optical Fiber Alignment Structure
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Solution Overview
Problem
Existing optical fiber alignment systems, particularly those using ferrules, face challenges in achieving precise alignment due to high manufacturing costs and difficulties in drilling accurate central holes, while ferrule-less solutions like V-grooves require complex positioning and may not provide optimal optical coupling.
Innovation Solution
A self-centering structure using cantilever members to align optical fibers end-to-end, which can be assembled in a module or split sleeve, reduces the number of parts and costs, and utilizes index matching gel to enhance optical coupling by minimizing Fresnel reflections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ferrule-based alignment systems are used, then fiber alignment precision can be achieved, but manufacturing cost increases and central hole drilling becomes difficult
Solution Approach 1:
The patent removes the ferrule component entirely from the alignment system. Instead of using ferrules with precision holes, the invention uses a V-groove structure that directly guides and aligns the optical fibers without requiring any ferrule components, thereby eliminating the difficult central hole drilling process and reducing manufacturing complexity
Solution Approach 2:
The patent replaces expensive ferrule-based alignment systems with a simpler, more economical V-groove structure. The V-groove alignment device uses basic geometric features and standard manufacturing techniques to achieve the same alignment function at lower cost, making the alignment system more accessible and easier to produce
2Ease of manufacture
If V-groove alignment is used, then manufacturing cost is reduced, but positioning complexity increases and optical coupling may not be optimal
Solution Approach 1:
The patent employs asymmetric V-groove geometries with specific angle configurations that naturally guide fiber positioning. The asymmetric design of the V-grooves creates inherent alignment cues that simplify the positioning process while maintaining manufacturing simplicity, resolving the contradiction between cost reduction and positioning complexity
Solution Approach 2:
The patent utilizes curved surfaces and rounded features in the V-groove structure to facilitate smooth fiber insertion and alignment. The curved geometry of the V-grooves provides gradual guidance for fiber positioning, reducing the complexity of precise alignment while maintaining the cost advantages of the ferrule-less design
3Ease of manufacture
If V-groove alignment is used, then manufacturing cost is reduced, but optical coupling efficiency may be compromised
Solution Approach 1:
The patent optimizes the geometric parameters of the V-groove structure, including groove angles, depths, and spacing, to achieve optimal optical coupling. By carefully selecting and adjusting these parameters, the V-groove alignment system achieves reliable optical coupling efficiency comparable to ferrule-based systems while maintaining manufacturing cost advantages
Solution Approach 2:
The patent applies localized structural features within the V-groove alignment device that specifically enhance optical coupling at the fiber interface. Local modifications such as optimized groove geometries at the fiber contact points and index matching gel application areas ensure high optical coupling efficiency without compromising the overall manufacturing simplicity and cost-effectiveness of the system
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
The self-centering structure effectively aligns optical fibers with reduced manufacturing costs and improved optical efficiency by using a minimal number of parts and index matching gel to enhance optical coupling, addressing the limitations of ferrule-based and ferrule-less alignment methods.
Implementation Method 1
Index matching gel can be used with alignment devices in accordance with the principles of the present disclosure to improve the optical connection between the open light transmission paths of the first and second optical fibers. The index matching gel preferably has an index of refraction that closely approximates that of an optical fiber is used to reduce Fresnel reflection at the surface of the bare optical fiber ends.
Data Source
AI summary
A self-centering structure (300) for aligning optical fibers (308) desired to be optically coupled together is disclosed. The self-centering structure (300) including a body (310) having a first end (312) and a second end (314). The first end (312) defines a first opening (303) and the second end (314) defines a second opening (304). The self-centering structure (300) includes a plurality of groove structures (306) integrally formed in the body (310) of the self-centering structure for receiving the optical fibers (308) and a fiber alignment region (305) positioned at an intermediate location between the first and second ends (312, 314) to facilitate centering and alignment of the optical fibers (308). The plurality of cantilever members (322) is flexible and configured for urging the optical fibers (308) into their respective groove structures (306).