Shaped Capillary for Fiber Bundle Alignment

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Solution Overview

Problem

Standard capillary structures with circular or substantially circular inner peripheries pose challenges in fiber alignment, fusing, and brightness conversion due to mismatched shapes between the fiber bundle and the capillary, leading to issues like fiber twist, crossover, jamming, and deformation.

Innovation Solution

A high-brightness combiner using a shaped capillary structure with an inner periphery that corresponds to the shape of the fiber bundle's outer periphery, which reduces interstitial spaces and minimizes fiber deformation during fusing and tapering.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a standard circular capillary structure is used, then the manufacturing process is simple, but fiber alignment is poor and fiber deformation occurs during fusing

Engineering Contradiction:

Improvecapillary manufacturing simplicityVSAvoidfiber alignment precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The capillary structure transitions from a standard circular geometry to a non-circular shaped capillary that matches the packing geometry of the fiber bundle. This asymmetric design eliminates the shape mismatch between the capillary and fiber bundle, preventing fiber twist, crossover, and jamming during the fusing process while maintaining manufacturing feasibility through specialized molding techniques.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The capillary structure is designed with locally optimized features including a shaped inner periphery that conforms to the fiber bundle packing geometry, and a tapered outer periphery that facilitates fiber fusion. The capillary wall thickness and opening dimensions are specifically engineered at different locations to accommodate the fiber bundle configuration and enable controlled fusing.

Inventive Principle:

Principle #3Local quality

2Device complexity

If a circular capillary is used with non-circular fiber bundle, then the capillary structure is simple, but interstitial spaces increase causing fiber deformation

Engineering Contradiction:

Improvecapillary structure complexityVSAvoidfiber bundle integrity

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The capillary inner periphery is designed with a non-circular shape that precisely matches the packing geometry of the fiber bundle (e.g., hexagonal or rectangular arrangements). This asymmetric matching eliminates wasted interstitial spaces and ensures uniform contact between fibers and capillary walls during fusing, preventing fiber deformation and maintaining bundle integrity.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The capillary structure is pre-shaped and pre-tapered before fiber loading to establish the optimal geometric configuration. The inner periphery is formed to match the target fiber bundle arrangement, and the outer periphery is tapered to facilitate controlled fusing, ensuring that fibers are guided into the correct positions and maintained in the desired configuration throughout the manufacturing process.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If standard capillary geometry is used, then manufacturing is easier, but brightness conversion is reduced due to air gaps and contamination

Engineering Contradiction:

Improvecapillary fabrication easeVSAvoidbrightness conversion efficiency

Core Design Contradiction:

Ease of manufactureVSIllumination intensity

Solution Approach 1:

The non-circular shaped capillary eliminates air gaps between the fiber bundle and capillary walls by matching the fiber packing geometry. This geometric precision ensures intimate contact between fibers and capillary interior surfaces, minimizing air pockets that would scatter light and reducing contamination pathways, thereby maximizing brightness conversion efficiency.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The capillary structure incorporates controlled wall thickness variations and opening dimension optimizations to enhance optical performance. The tapered outer periphery and shaped inner periphery create optimal parameters for light transmission and fiber fusion, improving brightness conversion while maintaining manufacturability through precision molding techniques.

Inventive Principle:

Principle #35Parameter changes

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 shaped capillary structure enhances fiber alignment, reduces deformation, and improves brightness conversion by maintaining the circularity of the fiber bundle and minimizing air gaps and contamination, thereby improving the overall efficiency and manufacturability of the combiner.

Implementation Method 1

tapering the capillary structure while a heat source is applied along a length of the outer periphery of the capillary structure

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS20250130370A1High-brightness combiner with shaped capillary

Publication Date: 2025.04.24 WELLS FARGO BANK NA

AI summary

In some implementations, a high-brightness combiner comprises a fiber bundle that comprises a plurality of optical fibers associated with a packing geometry that defines a shape of an outer periphery of the fiber bundle. The high-brightness combiner further comprises a capillary structure, comprising a glass enclosure surrounding the fiber bundle, wherein the capillary structure includes an outer periphery, and an inner periphery with a shape that corresponds to the shape of the outer periphery of the fiber bundle.