Two-Layer Fiber Array Core Pitch Measurement on Angled End Faces
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Solution Overview
Problem
Current measurement devices are limited in their ability to accurately determine vertical components of core pitch values in two-dimensional fiber array units, especially when the end face is angled, leading to inaccurate assessments of optical fiber positioning and increased yield losses due to tolerance violations.
Innovation Solution
A method for determining core pitch values in two-dimensional fiber array units with an angled end face by adjusting vertical components using equations that account for the angle of the end face, allowing for precise measurement and calculation of core pitch errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If current measurement devices are used to determine core pitch values in two-dimensional fiber array units with angled end faces, then the measurement process is simple, but the measurement precision deteriorates due to inaccurate vertical component determination
Solution Approach 1:
The patent introduces an intermediary calculation method that uses trigonometric relationships and reference frames to mediate between the measured beam positions and the actual core pitch values. By creating a mathematical model that accounts for the angled end face geometry, the system accurately determines vertical components without requiring complex physical measurement apparatus.
Solution Approach 2:
The patent replaces complex mechanical measurement systems with an optical measurement approach combined with computational geometry. Instead of using mechanical devices to directly measure angled surfaces, the system uses optical beam positioning combined with mathematical calculations to derive accurate core pitch values, substituting mechanical complexity with computational precision.
2Reliability
If tolerance ranges are applied to account for coupling losses, then yield losses are reduced, but manufacturing precision deteriorates due to the difficulty of achieving accurate core pitch values at micron scales
Solution Approach 1:
The patent implements a feedback mechanism where measured core pitch values are compared against tolerance ranges, and the results feed back into the measurement and manufacturing processes. By continuously monitoring and adjusting based on measured deviations, the system maintains reliability while providing precise feedback for manufacturing improvements.
Solution Approach 2:
The patent changes the approach from attempting to achieve perfect precision to measuring and characterizing actual deviations within tolerance ranges. By adjusting the measurement methodology to account for systematic errors and using statistical tolerance analysis, the system achieves reliable data transfer while accepting and managing manufacturing variations.
3Productivity
If fiber array units are manufactured on a micron scale, then data transfer efficiency is improved, but measurement precision deteriorates because small errors result in large yield losses
Solution Approach 1:
The patent adds a mathematical dimension to the measurement problem by introducing trigonometric calculations and reference frame transformations. By moving from direct physical measurement to a combination of optical measurement and computational geometry, the system achieves the precision needed for micron-scale manufacturing while maintaining high data transfer efficiency.
Data Source
AI summary
A method for determining a core pitch value and/or error of an optical fiber positioned in a two-dimensional fiber array unit is provided herein. The fiber array unit includes a first layer and a second layer of optical fibers. The method comprises positioning one of the fiber array unit or a core pitch measurement device relative to each other to enable measurement of at least one core pitch value. The method continues by measuring a first horizontal and vertical component corresponding to a first optical fiber in the first layer, and a second horizontal component and a vertical component corresponding to the optical fiber in the second layer. The method continues by determining an adjusted second vertical component based on an angle of the end face of the fiber array unit, the first vertical component and the second vertical component, and determining a core pitch value and/or error therefrom.