Wedge-Shaped Fiber Optic Dielectric Waveguide Structure

Solution Overview

Problem

Current methods for fabricating optical fiber modal multichannel duplex devices are hazardous, unreliable, and costly due to the use of harsh chemicals like hydrofluoric acid, making them unsuitable for mass production and environmentally friendly applications.

Innovation Solution

A novel mechanical polishing method is employed to create a wedge-shaped fiber optic dielectric waveguide structure that modulates and radiates standing waveguide and linearly polarized modes without using caustic chemicals, allowing for repeatable and reliable production of optical fiber ends.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If hydrofluoric acid chemical etching process is used to create cone-shaped optical fiber tips, then the fiber tips can be etched to a very fine point for modal ring radiation, but the process becomes hazardous, unreliable, costly, and environmentally unfriendly

Engineering Contradiction:

Improvefiber tip precisionVSAvoidchemical hazard

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the chemical etching process with a mechanical polishing process. Specifically, it uses a mechanical polishing device with a polishing head containing multiple polishing elements that mechanically ablate the optical fiber tip to create the desired conical shape, eliminating the need for hydrofluoric acid and other hazardous chemicals while achieving precise fiber tip geometry

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent converts the potentially harmful chemical etching process into a beneficial mechanical polishing process. By using controlled mechanical abrasion with progressively finer polishing elements, the harmful chemical reactions are replaced with a clean, controllable mechanical removal process that achieves the same geometric outcome without environmental or safety hazards

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Reliability

If hydrofluoric acid etching is used to create cone-shaped fiber tips, then modal ring radiation can be achieved, but the process is not repeatable and requires significant experience to refine

Engineering Contradiction:

Improveprocess repeatabilityVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent segments the polishing process into multiple discrete stages, each with specific polishing elements of defined geometry and material properties. The polishing head contains multiple polishing elements that work in sequence, with each element performing a specific function (coarse shaping, intermediate finishing, fine polishing), making the overall process more controllable and repeatable

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent systematically changes physical parameters of the polishing process, including the geometry, material, and arrangement of polishing elements, as well as the polishing pressure and speed. These controlled parameter changes allow for precise control over the fiber tip geometry achievement, ensuring repeatability across different manufacturing runs

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If chemical etching processes are used for optical fiber fabrication, then fiber tip shaping is achieved, but the processes are expensive and difficult to achieve consistently

Engineering Contradiction:

Improvemanufacturing easeVSAvoidfiber tip consistency

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent designs the mechanical polishing system to be self-regulating, where the polishing elements automatically maintain consistent contact with the fiber tip through their mechanical arrangement and material properties. The system self-adjusts to maintain consistent polishing pressure and geometry without requiring constant operator intervention or expertise, making the process easier to manufacture consistently

Inventive Principle:

Principle #25Self-service

4Shape

If hydrofluoric acid solutions are used for etching optical fiber tips, then cone shape can be created, but storage and disposal control becomes costly and prohibitive

Engineering Contradiction:

Improvecone shapeVSAvoidenvironmental impact

Core Design Contradiction:

ShapeVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the chemical etching process with a mechanical polishing process. Specifically, it uses a mechanical polishing device with a polishing head containing multiple polishing elements that mechanically ablate the optical fiber tip to create the desired conical shape, eliminating the need for hydrofluoric acid and other hazardous chemicals while achieving precise fiber tip geometry

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent converts the potentially harmful chemical etching process into a beneficial mechanical polishing process. By using controlled mechanical abrasion with progressively finer polishing elements, the harmful chemical reactions are replaced with a clean, controllable mechanical removal process that achieves the same geometric outcome without environmental or safety hazards

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 approach enables efficient and cost-effective fabrication of optical fiber modal multiplexing and de-multiplexing systems, reducing safety risks and environmental impact while improving repeatability and reliability, facilitating their transition into commercial applications.

Implementation Method 1

A novel apparatus and method for mechanically polishing optical fibers to achieve the dielectric waveguide wedge endface and lip of the invention is also disclosed

Methodology Applied

Scientific EffectMechanical polishing: Abrasion

Implementation Method 2

A fiber optic dielectric waveguide structure for modal multiplexed communication... wedge-shaped fiber optic dielectric waveguide structure for optical fiber ends for radiating and/or modulating standing waveguide modes and linearly polarized modes

Methodology Applied

Scientific EffectWaveguide mode radiation: Waveguide (optics)

Data Source

PatentUS9597765B2Fiber optic dielectric waveguide structure for modal multiplexed communication and method of manufacture

Publication Date: 2017.03.21 SPARTON DELEON SPRINGS LLC

AI summary

A novel optical fiber end structure and method for creating same in which an optical fiber end structure may comprise a cylindrical wedge having a planar surface angled with respect to the longitudinal axis of the optical fiber and a flat surface that is generally perpendicular with the longitudinal axis of the optical fiber. The device and method of the invention may employ a single or plurality of mechanically polished wedges on the end or ends of an optical fiber, which may, in a best mode, be a few mode fiber. The method and device of the invention may be used to independently modulate standing waves or linearly polarized waves, or both, allowing for a modal multiplexed system. The invention radiates independent standing wave modes and/or linearly polarized modes from the dielectric waveguide structure, and may be employed in single, few mode or multimode optical fibers.