Optical Fiber Connector With Tapered Waveguide Core
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Solution Overview
Problem
Existing optical fiber connector assembly processes are costly and prone to errors due to high precision requirements and susceptibility to dust or dirt, making them challenging for high-volume production and increasing component costs.
Innovation Solution
The development of an optical fiber connector with a waveguide section integrally formed with a fiber attachment section, featuring a larger core cross-section at one end to reduce alignment accuracy needs and incorporate features like tapered regions and antireflection coatings to minimize losses, along with a manufacturing method that includes forming waveguides in a substrate with varying core cross-sections for improved alignment and light transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high precision molding and positioning are used for MT ferrule connectors, then alignment accuracy is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent changes the physical parameters of the waveguide by implementing a tapered structure where the core cross-section area varies along the propagation direction. The first end has a smaller core cross-section area for precise fiber coupling, while the second end has a larger core cross-section area that is easier to align with other waveguides or fibers, thereby reducing alignment complexity without sacrificing connection precision
Solution Approach 2:
The waveguide is divided into distinct sections with different core cross-section areas along its length. The tapered region creates a gradual transition between the smaller first end and the larger second end, allowing each section to serve its specific function: precise coupling at the first end and easier alignment at the second end, thus reducing overall assembly complexity
2Reliability
If tight tolerance positioning is used for fiber locating holes, then connection reliability is improved, but manufacturing cost increases
Solution Approach 1:
By implementing a tapered waveguide structure where the core cross-section area increases from the first end to the second end, the patent reduces the manufacturing tolerance requirements at the second end while maintaining reliable connection. The larger core area at the second end provides a larger coupling aperture that is more tolerant to positioning variations, thereby reducing manufacturing cost while preserving connection reliability
3Manufacturing precision
If manual assembly processes are used for optical fiber connectors, then alignment precision is improved, but productivity decreases
Solution Approach 1:
The tapered waveguide structure with its varying core cross-section area provides built-in alignment guidance that reduces the need for manual precision alignment. The gradual transition in the tapered region creates natural alignment cues that facilitate automated assembly processes, thereby increasing productivity while maintaining adequate alignment precision through the geometric design rather than manual skill
4Manufacturing precision
If high precision molding is used for ferrule components, then component quality is improved, but component cost increases
Solution Approach 1:
The patent employs a tapered waveguide structure where the core cross-section area varies along the length, with the first end having a smaller area and the second end having a larger area. This geometric parameter change reduces the precision requirements for molding and assembly at the second end while maintaining high quality connection at the first end, thereby reducing component cost without sacrificing overall component quality
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 solution simplifies the assembly process, reduces alignment errors, and minimizes light losses due to dust or reflective issues, making the connectors easier to produce and more reliable, thus lowering costs and enhancing performance.
Implementation Method 1
The at least a first waveguide has a first core cross-section at the first end of the waveguide section and a second core cross-section at the second end of the waveguide section. The second core cross-section has an area larger than an area of the first core cross-section.
Implementation Method 2
incorporate features like tapered regions and antireflection coatings to minimize losses
Data Source
AI summary
An optical fiber connector includes a coupler having a waveguide section integrally formed with a fiber attachment section. At least one waveguide is disposed in the waveguide section and has a core dimension that is greater at the end of the waveguide at the fiber attachment section. The fiber attachment section has a first surface and at least one recess formed on the first surface for aligning one or more optical fibers with the at least one waveguide. In an optical fiber component, an optical substrate has a first end and a second end, and at least one waveguide input at the first end and at least one waveguide output at the second end. An integral input portion of the substrate at the first end has one or more input optical fiber alignment elements and an integral output portion of the substrate at the second end has one or more output optical fiber alignment elements. One or more input optical fibers are positioned in the one or more input optical fiber alignment elements. One or more output optical fibers positioned in the one or more output optical fiber alignment elements.