Unitary Substrate Optical Connector with Staggered Microlenses
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Solution Overview
Problem
Current expanded beam multiple fiber connectors limit the beam diameter to match the fiber ribbon pitch, requiring manual separation of fibers for connections with a diameter greater than the pitch, and are sensitive to contamination.
Innovation Solution
A unitary substrate with staggered light redirecting features and microlenses allows for the redirection and focusing of optical beams without separating fibers, enabling a larger beam diameter and improved resistance to contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If current expanded beam multiple fiber connectors are used, then the beam diameter is limited to match the fiber ribbon pitch, but manual separation of fibers is required for connections with a diameter greater than the pitch
Solution Approach 1:
The patent introduces a third dimension by tilting the light redirecting surface at an oblique angle (e.g., 45 degrees) relative to the input surface. This angular dimension allows the optical beam to be redirected perpendicular to the fiber axis while maintaining a compact footprint, enabling larger beam diameters without increasing the connector's linear dimensions or requiring fiber separation.
Solution Approach 2:
The unitary substrate integrates multiple functions: it provides mechanical support, guides fiber alignment through vee-grooves, redirects light at oblique angles, and positions microlenses. This multi-functionality eliminates the need for separate components and manual fiber separation, allowing the connector to handle various beam diameters while maintaining simplicity.
2Measurement precision
If physical contact connectors are used, then alignment precision is achieved, but dust on fiber tips greatly increases light loss
Solution Approach 1:
The patent introduces microlenses as intermediary elements between the optical fibers. These microlenses focus or collimate the light beam, creating an expanded beam path that is less sensitive to dust particles on the fiber tips. The microlenses act as mediators that transform the light propagation mode from direct contact-sensitive to expanded beam-tolerant.
Solution Approach 2:
The patent changes the beam diameter parameter by using microlenses to expand the light beam beyond the fiber core diameter. This parameter change from a narrow focused beam to an expanded beam reduces the impact of dust particles, as the light distribution over a larger area makes the connection less sensitive to small contaminants on the fiber surfaces.
3Area of moving object
If fiber ribbons are manually split into single fibers, then beam diameter greater than fiber pitch is achieved, but connection time and complexity increase
Solution Approach 1:
The patent segments the light beam into multiple discrete paths using individual microlenses for each fiber position. This segmentation allows each fiber in the ribbon to be independently coupled to its corresponding microlens while maintaining the ribbon's integrity, eliminating the need to manually separate fibers while still achieving the desired beam diameter through the microlens expansion capability.
4Ease of manufacture
If conventional connector designs are used, then manufacturing simplicity is maintained, but beam diameter is limited to match fiber pitch
Solution Approach 1:
The patent merges the light redirecting feature and microlens into a single unitary substrate. This integration combines multiple optical functions into one manufacturable component that can be produced using standard semiconductor or optical fabrication techniques. The unified design maintains manufacturing simplicity while enabling larger beam diameters through the integrated oblique angle redirection and microlens focusing.
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
Enables efficient, compact, and reliable connections of optical fiber ribbons with a beam diameter greater than the fiber-to-fiber pitch, reducing sensitivity to dust and other contaminants, and simplifying the connection process.
Implementation Method 1
the light redirecting surface making an oblique angle with the input surface
Implementation Method 2
a light redirecting surface for redirecting the received light to the corresponding microlens
Implementation Method 3
the light is collimated to form a beam with a diameter substantially greater than the core
Implementation Method 4
an opposing second major surface having a plurality of staggered microlenses
Data Source
AI summary
The disclosure generally relates to sets of optical waveguides such as optical fiber ribbons, and fiber optic connectors useful for connecting multiple optical fibers such as in optical fiber ribbon cables. In particular, the disclosure provides an efficient, compact, and reliable optical fiber connector that incorporates a unitary substrate combining the features of optical fiber alignment and redirection of the optical beam to a connected optical fiber.