Waveguide Substrates with Projecting Bosses for Ferrule Alignment
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Solution Overview
Problem
Current waveguide substrates for optical connections face challenges in managing and routing optical fibers efficiently within compact equipment, limiting their widespread adoption in optical communication networks.
Innovation Solution
A waveguide substrate design featuring projecting bosses with bores and slots for ferrule alignment, along with relief cavities to accommodate connector bodies, facilitates efficient optical signal routing and connectivity with optical connectors, enabling the use of waveguide substrates as a substitute for optical fibers in network equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If optical fibers are used to route optical signals within bodies or housings, then optical signal routing is achieved, but managing connections and routing/placement becomes challenging and equipment size increases
Solution Approach 1:
The patent replaces traditional mechanical optical fiber routing with a waveguide substrate that uses integrated waveguides etched into a glass or ceramic plate. This substitution eliminates the need for manual fiber management and routing, as the waveguides are pre-configured in fixed patterns that automatically guide optical signals between connectors, thereby simplifying operation and reducing equipment complexity.
2Productivity
If waveguide substrates are used to substitute for optical fiber routing, then optical signal routing efficiency improves and equipment size reduces, but connection alignment precision and ferrule positioning become more critical
Solution Approach 1:
The patent introduces alignment features such as protrusions on the waveguide substrate that mate with corresponding recesses in the connector bodies, and positioning holes that receive alignment pins. These intermediary alignment mechanisms act as mediators between the waveguide substrate and connectors, ensuring precise ferrule positioning and alignment without requiring high manufacturing precision across all components individually.
Solution Approach 2:
The alignment features are pre-configured on the waveguide substrate during manufacturing, with protrusions and positioning holes located at specific coordinates that correspond to the required ferrule positions. This preliminary action of pre-positioning alignment features eliminates the need for complex alignment procedures during assembly, as the features automatically guide connectors into the correct positions.
3Measurement precision
If projecting bosses with bores are used for ferrule reception, then connector alignment and positioning improve, but waveguide substrate structural complexity increases
Solution Approach 1:
The projecting bosses serve multiple functions simultaneously: they provide mechanical support for the waveguide substrate, contain the bores for ferrule reception and alignment, and feature slots that accommodate connector body portions. This multi-functionality reduces the need for separate alignment features and support structures, thereby limiting the increase in overall structural complexity while achieving precise connector positioning.
Data Source
AI summary
A waveguide substrate configured includes a first surface, a second surface opposite the first surface, and a communication side having at least one projecting boss that at least partially defines a bore for receiving a ferrule of an optical connector. Each projecting boss includes an outboard end from which the bore extends into the waveguide substrate, and an end of the bore within the waveguide substrate defines an optical interface surface. At least one waveguide within the waveguide substrate extends from the optical interface surface. A first slot is formed in each projecting boss between the associated bore and the first surface, with the first slot extending from the outboard end of the projecting boss and along a majority of the bore.