Stamped V-Groove Coupling Device for Optical Fiber Alignment
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Solution Overview
Problem
Existing fiber optic signal transmission systems face challenges with bulky, expensive, and complex structures for precise optical alignment, which are not suitable for smaller devices and are costly to produce, especially in multi-channel applications.
Innovation Solution
A coupling device with a structured reflective surface and fiber retention structure that securely aligns optical fibers using reflection, deflection, and diffraction, allowing for precise alignment and easy integration with transmitters and receivers, fabricated using low-cost, high-throughput processes like stamping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional coupling structures with internal optical elements are used to achieve precise optical alignment, then optical alignment precision is improved, but device size and complexity increase significantly
Solution Approach 1:
The patent combines the optical alignment function and fiber retention function into a single integrated coupling structure. The V-groove geometry simultaneously provides mechanical fiber positioning and optical axis alignment, eliminating the need for separate alignment mechanisms and reducing overall device complexity while maintaining sub-micron alignment precision.
Solution Approach 2:
The patent replaces complex mechanical alignment systems with a geometrically-defined V-groove structure. Instead of using adjustable mechanical elements or multiple components to achieve alignment, the fixed angular geometry of the V-groove inherently guides the fiber to the correct optical position, simplifying the mechanical system while preserving alignment precision.
2Manufacturing precision
If traditional coupling structures with connection ports are used, then optical alignment is achieved, but device size increases making them unsuitable for compact applications
Solution Approach 1:
The patent merges the alignment function and retention function into a single compact V-groove structure, eliminating the need for separate connection ports and internal optical elements. This integration dramatically reduces the device volume while maintaining sub-micron alignment precision through the geometric definition of the groove.
Solution Approach 2:
The patent extracts and eliminates unnecessary internal optical elements and complex connection port structures from traditional coupling designs. Only the essential V-groove geometry is retained, which provides both alignment and retention functions in a minimal space, making the device suitable for compact applications.
3Manufacturing precision
If sub-micron precision assembly is performed manually for multi-channel fiber transmission, then alignment precision is improved, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent incorporates preliminary action by pre-defining the optical alignment geometry in the V-groove structure during manufacturing. The groove geometry is precisely formed in advance with the correct angular dimensions, so that fiber insertion automatically achieves sub-micron alignment without requiring time-consuming manual adjustment or measurement during assembly.
Solution Approach 2:
The V-groove structure provides self-alignment functionality, where the fiber automatically positions itself correctly through the geometric constraints of the groove. This self-service mechanism eliminates the need for operator intervention or complex alignment procedures, enabling high-speed automated assembly while maintaining sub-micron precision.
4Reliability
If traditional expensive coupling structures are used, then optical performance is maintained, but manufacturing cost increases
Solution Approach 1:
The patent employs a simple V-groove structure that can be manufactured using low-cost processes such as precision stamping or molding. This replaces expensive traditional coupling structures with internal optical elements, achieving the same optical coupling reliability through geometric design rather than expensive materials or complex assemblies.
Solution Approach 2:
The patent substitutes complex mechanical alignment systems with a geometrically-defined V-groove structure that can be manufactured at low cost. The optical coupling reliability is achieved through the precise geometry of the groove rather than through expensive mechanical adjustment mechanisms or internal optical components.
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 solution improves manufacturability, ease of use, and reliability while reducing costs, enabling efficient optical signal routing with high precision and adaptability for single or multiple fibers in compact designs.
Implementation Method 1
The device includes a structured surface that functions as an optical element that directs light to/from the input/output ends of the optical fiber by reflection (which may also include deflection and diffraction of incident light).
Data Source
AI summary
A process of making a coupling device for physically and optically coupling an optical fiber to route optical signals to/from optical receiver/transmitter. The coupling device includes a structured reflective surface that functions as an optical element that directs light to/from the input/output ends of the optical fiber by reflection, and an optical fiber retention groove structure that positively receives the optical fiber in a manner with the end of the optical fiber at a defined distance to and aligned with the structured reflective surface. The open structure of the structured reflective surface and fiber retention structure lends itself to mass production processes such as precision stamping. The coupling device can be attached to an optical transmitter and/or receiver, with the structured reflective surface aligned to the light source in the transmitter or to the detector in the receiver, and adapted in an active optical cable.