Waveguide Arrays With Groove-Break Clean Ends
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Solution Overview
Problem
The challenge in manufacturing high-speed computer circuit boards lies in the inaccuracy and time-consuming process of physically connecting fiber optics, which is exacerbated by the deformation and burr formation during conventional machining of small plastic parts used for optical interconnections, leading to energy loss and optical signal scattering.
Innovation Solution
A waveguide array is created with clean end surfaces by breaking a base portion along a strategically positioned groove, allowing for the attachment of a metalized cover portion to form pristine end surfaces that minimize energy loss and eliminate the need for deburring, using methods like molding, etching, or machining to prepare the groove and channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining (saw cutting or milling) is used to create clean edges on small plastic parts, then edge cleanliness is improved, but burrs and breakages form at the edge, worsening manufacturing quality
Solution Approach 1:
The patent applies preliminary action by forming a groove at the desired break location before the actual breaking operation. This groove serves as a stress concentration point that guides the break to occur precisely at the intended location, preventing uncontrolled breakage and burr formation that would otherwise occur with conventional machining methods
Solution Approach 2:
The patent replaces the mechanical machining system (saw cutting or milling) with a breaking system. Instead of using cutting tools that generate burrs and breakages, the invention uses a controlled breaking process initiated by a pre-formed groove, substituting mechanical removal with mechanical fracture that produces cleaner edges
2Manufacturing precision
If plastic parts are molded with fine details for optical interconnection, then optical precision is improved, but shrinkage and deformation occur at end faces, worsening dimensional accuracy
Solution Approach 1:
The groove is formed in advance during the molding process or before breaking, allowing the plastic to set in its final shape before the break occurs. This preliminary action ensures that the fine optical details are established while the material is still in its molded state, and the subsequent break occurs at a controlled location away from the critical optical surfaces
Solution Approach 2:
The patent segments the plastic component into two portions by breaking at the groove location. This segmentation allows the critical end faces that require optical precision to remain intact and undeformed, while the break occurs at a non-critical location where deformation is acceptable or can be managed
3Manufacturing precision
If physical connection of fiber optics is performed manually, then connection accuracy is improved, but manufacturing time increases significantly, worsening productivity
Solution Approach 1:
The patent merges multiple fiber optic connections into a single integrated waveguide array structure. Instead of manually connecting individual fiber optics one by one, the invention provides a pre-formed array with multiple channels that can accommodate multiple connections simultaneously, dramatically reducing the time required while maintaining connection accuracy through the precise groove positioning and controlled break
Data Source
AI summary
A waveguide array can comprise a base portion having a metalized inner surface, an outer surface, and a clean end surface. The inner surface can include a plurality of waveguide channels that are metalized. The clean end surface can be prepared by breaking the base portion along a groove positioned on the outer surface prior to breaking, where the groove is oriented to intersect the waveguide channels. A metalized cover portion is attached to the inner surface of the base portion to close the waveguide channels.