Staggered Fusion Parts in Optical Fiber Arrays
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Solution Overview
Problem
High-density optical fiber arrays face interference issues due to expanding fusion parts of adjacent optical fibers, which hinder precise alignment and placement in fiber grooves on a substrate.
Innovation Solution
The optical fiber array design features a substrate with staggered positions of fusion parts along the longitudinal direction, utilizing clearance parts to accommodate the expanded diameter of fusion parts, preventing interference and ensuring precise alignment through strategically placed fiber grooves and a fixing member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If optical fibers are placed at high density on a substrate, then the quantity of optical fibers per unit area increases, but the fusion parts of adjacent optical fibers interfere with each other, preventing proper placement in fiber grooves
Solution Approach 1:
The patent introduces a longitudinal dimension to the fiber groove structure by forming it with inclined surfaces that extend along the length of the optical fiber. This three-dimensional groove structure allows the expanded fusion parts to be accommodated at different longitudinal positions, effectively using the longitudinal dimension to resolve the interference problem while maintaining high lateral density of fibers.
Solution Approach 2:
The fiber groove is designed with different local properties: the inclined surfaces provide a tapered accommodation space for the expanded fusion parts, while the bottom of the groove provides stable support. This local differentiation in groove geometry allows each region to serve its specific function - the inclined portions accommodate the varying diameters of fusion parts while the flat bottom ensures stable positioning.
2Ease of manufacture
If fusion parts are positioned at the same location in the longitudinal direction for all optical fibers, then the manufacturing process is simplified, but adjacent fusion parts interfere with each other and prevent proper fiber placement
Solution Approach 1:
Instead of varying the lateral positions of fusion parts (which would complicate manufacturing), the patent uses the longitudinal dimension of the inclined fiber grooves to accommodate fusion parts at different longitudinal positions. This approach maintains manufacturing simplicity while ensuring reliable placement, as the inclined groove structure naturally guides and positions fibers along its length.
3Strength
If the outer diameter of fusion parts increases beyond the optical fiber diameter, then the fusion splice is achieved, but the expanded fusion parts interfere with adjacent optical fibers and prevent proper alignment
Solution Approach 1:
The fiber groove is designed with inclined surfaces that create a localized expanded space specifically for accommodating the larger diameter fusion parts. This local geometric adaptation allows the fusion parts to maintain their necessary expanded diameter for strong splices while the inclined groove walls prevent interference with adjacent fibers by providing a tapered containment structure.
Solution Approach 2:
The inclined fiber groove utilizes the longitudinal dimension to accommodate the radial expansion of fusion parts. By extending the groove along the longitudinal axis with inclined surfaces, the structure provides vertical clearance for the expanded fusion diameter while maintaining lateral compactness to prevent interference between adjacent fibers.
Data Source
AI summary
An optical fiber array includes: optical fibers that each include a fusion part; and a substrate on which fiber grooves are formed along a longitudinal direction of the optical fibers. The optical fibers are aligned in a width direction of the optical fibers. The fiber grooves are aligned in the width direction. The fusion parts are disposed on the substrate. The fusion parts of two adjacent optical fibers are disposed in different positions from each other in the longitudinal direction.