Stackable Positioning Device for Optical Fiber Alignment

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Solution Overview

Problem

Existing optical fiber array systems face challenges in precisely aligning multiple fiber terminators for coherent and spectral beam combination, which is crucial for achieving high-power laser beams required in materials processing and machining, as individual fiber lasers typically provide limited power and require precise alignment of beams in crowded optical setups.

Innovation Solution

A positioning device and alignment fixture that includes a stackable design with adjustable positioning devices, allowing for precise in-plane position and yaw control of optical fiber terminators, which can be aligned from the light-receiving end without accessing the light-emitting end, providing a robust and thermally efficient solution for beam combination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple fiber terminators are positioned in a solid structure with grooves, then the fiber ends are oriented parallel to each other, but the alignment precision is insufficient for high-power beam combination

Engineering Contradiction:

Improvealignment precisionVSAvoidpositioning structure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The positioning structure is divided into multiple independent positioning devices, each responsible for holding and aligning a single fiber terminator. Each positioning device can be independently adjusted and clamped, allowing precise control of individual fiber positions without affecting others, thereby achieving high alignment precision while maintaining manageable device complexity through modular design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The positioning devices incorporate adjustable elements that allow dynamic modification of fiber terminator positions. The ability to adjust and clamp each positioning device independently enables fine-tuning of alignment precision after assembly, transforming a static rigid structure into a dynamically adjustable system that achieves superior alignment.

Inventive Principle:

Principle #15Dynamics

2Power

If fiber arrays are used for beam combination, then higher laser power is achieved, but the space at the light-emitting end becomes crowded

Engineering Contradiction:

Improvelaser powerVSAvoidspace at light-emitting end

Core Design Contradiction:

PowerVSArea of stationary object

Solution Approach 1:

The alignment fixture enables alignment operations to be performed from the light-receiving end rather than requiring access to the light-emitting end. This dimensional shift in the alignment approach eliminates the need for crowded space at the light-emitting end, allowing multiple fiber terminators to be precisely aligned from the opposite direction while maintaining compact configuration.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Manufacturing precision

If individual positioning devices are made adjustable for precise alignment, then alignment precision is improved, but the device complexity and difficulty of assembly increase

Engineering Contradiction:

Improvealignment precisionVSAvoidassembly ease

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The system is segmented into identical, modular positioning devices that can be manufactured using the same processes and then assembled through standardized interfaces. Each module contains the adjustment mechanism, but the modular nature allows parallel manufacturing and simplifies assembly by reducing the need for custom fitting, thereby maintaining ease of manufacture while achieving high precision through individual adjustment.

Inventive Principle:

Principle #1Segmentation

4Stability of the object's composition

If a robust structure is used to maintain alignment stability against vibrations, then alignment stability is improved, but heat dissipation becomes more difficult

Engineering Contradiction:

Improvealignment stabilityVSAvoidheat dissipation

Core Design Contradiction:

Stability of the object's compositionVSTemperature

Solution Approach 1:

The positioning devices incorporate localized thermal management features at specific heat-generating points, such as heat sinks or thermally conductive materials positioned near the fiber terminators and adjustment mechanisms. This allows the overall structure to remain robust for vibration resistance while providing dedicated thermal pathways at critical locations to maintain effective heat dissipation without compromising alignment stability.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12140807B2Positioning device and alignment fixture for linear optical fiber array

Publication Date: 2024.11.12 ATTALON SOLUTIONS INC

AI summary

A fixture for aligning a linear array of optical fiber terminators includes a base and a heightwise stack of positioning devices disposed on the base. Each positioning device includes an anchor secured to a lengthwise wall of a bracket coupled to the base, a terminator holder flexibly coupled to the anchor and having a lengthwise channel for holding a respective optical fiber terminator, and actuators controlling position and yaw of the terminator holder in a plane orthogonal to the heightwise direction. The terminator holder has planar top and bottom surfaces that define a height of the terminator holder and interface with the terminator holder of any adjacent positioning device. The fixture also includes a clamp for clamping the positioning device stack against the base after setting the in-plane position and yaw of each terminator holder. Individual positioning devices may be adjusted or replaced without disturbing the rest of the stack.