Self-Forming Waveguide Optical Connector Alignment
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Solution Overview
Problem
The existing optical connectors, such as PMT connectors, face challenges in accurately aligning optical axes between optical fibers and polymer waveguides due to dimensional accuracy discrepancies, leading to difficulties in achieving high-precision single mode connections.
Innovation Solution
An optical connector design featuring a self-forming waveguide formed by photocuring resin between a front-stage block with an optical fiber and a rear-stage block with a polymer waveguide, where the resin is irradiated from both sides to create a curved waveguide that compensates for optical axis deviations, ensuring accurate alignment and connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a PMT connector is used to connect optical fiber and polymer waveguide, then the connection structure is simple, but optical axis alignment accuracy deteriorates due to dimensional accuracy discrepancy
Solution Approach 1:
The patent introduces a self-forming waveguide as an intermediary component between the optical fiber and polymer waveguide. This self-forming waveguide is created by injecting uncured resin that automatically forms a waveguide structure with high precision, serving as a mediator to bridge the dimensional accuracy gap between the optical fiber (submicron accuracy) and the polymer waveguide fixing portion (10 μm accuracy), thereby achieving accurate optical axis alignment without complex positioning mechanisms
Solution Approach 2:
The patent utilizes the parameter change of resin from uncured to cured state through light irradiation. The uncured resin can flow and adapt to fill the space between optical components, and upon curing, it forms a stable self-forming waveguide with precise optical properties. This parameter change enables the resin to achieve both the flexibility needed for alignment and the stability required for permanent connection
2Manufacturing precision
If a special positioning mechanism (slit) is formed in the PMT connector to achieve accurate connection, then optical axis alignment accuracy improves, but manufacturing complexity and cost increase
Solution Approach 1:
The patent employs a self-forming waveguide that automatically forms the precise positioning structure without requiring external positioning mechanisms. The uncured resin self-organizes and cures to create the self-forming waveguide with the exact geometry needed for optical axis alignment, eliminating the need for manual formation of slits or other positioning features in the PMT connector, thereby simplifying manufacturing while achieving high precision
3Manufacturing precision
If resin curing light is irradiated from both sides of the optical fiber and polymer waveguide, then the self-forming waveguide formation is improved, but the device complexity increases
Solution Approach 1:
The patent performs preliminary action by arranging the optical fiber and polymer waveguide in their final positions before injecting and curing the self-forming waveguide material. This preliminary arrangement ensures that when the resin cures, it forms the self-forming waveguide with the correct geometry and position, eliminating the need for complex post-formation adjustment mechanisms or multi-step irradiation processes
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
This design enables accurate and low-loss connections between optical fibers and polymer waveguides, simplifying the manufacturing process and eliminating the need for specialized positioning mechanisms, thereby improving connection reliability and reducing costs.
Implementation Method 1
the self-forming waveguide is a portion cured by irradiation of resin curing light in a self-forming waveguide material arranged between the front-stage block and the rear-stage block
Data Source
AI summary
An optical connector (10) of the present invention includes a front-stage block (11) on which an optical fiber is mounted, a rear-stage block (12) on which a polymer waveguide is mounted, a self-forming waveguide (18) arranged between the front-stage block and the rear-stage block, the self-forming waveguide configured to connect the optical fiber and the polymer waveguide, and a cladding portion (19) formed around the self-forming waveguide, wherein the self-forming waveguide is a portion cured by irradiation of resin curing light in a self-forming waveguide material arranged between the front-stage block and the rear-stage block. Thus, the present invention can provide an optical connector that reduces a connection loss between an optical fiber and a polymer waveguide by a simple structure.