Arcuate Ferrule Multi-Channel Optical Insert Design
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Solution Overview
Problem
Existing multi-cavity optical connectors face challenges in accommodating multiple fiber channels due to space constraints and lack of interchangeability with traditional inserts, limiting their versatility and efficiency.
Innovation Solution
The development of a multi-channel optical insert with a ferrule having arcuate sides that conforms to the cavity of the outer housing, allowing for precise positioning and increased area for multiple fiber channels, enabling high channel density and interchangeability with existing connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If a traditional ferrule contained within an insert housing is used, then the insert structure is conventional and easy to manufacture, but the available area for fiber channels is limited due to space constraints
Solution Approach 1:
The ferrule is extracted from the traditional insert housing configuration and configured to directly conform to the cavity wall. This removes the intermediate housing structure, allowing the ferrule end face to expand and accommodate more fiber channels while maintaining compatibility with existing connector cavities
Solution Approach 2:
The ferrule transitions from a conventional cylindrical shape to an arcuate cross-sectional shape that matches the cavity geometry. This dimensional change optimizes space utilization within the cavity, maximizing the ferrule end face area available for fiber channels
2Adaptability or versatility
If the ferrule is configured with arcuate sides to conform to the cavity, then channel density is increased and interchangeability is achieved, but manufacturing precision requirements are increased
Solution Approach 1:
The arcuate ferrule design serves multiple functions: it provides precise positioning within the cavity through wall contact, enables interchangeability with existing connectors, and maximizes fiber channel capacity. The same geometric feature addresses multiple design requirements simultaneously
3Measurement precision
If the ferrule is configured with arcuate sides to conform to the cavity, then the ferrule's position within the cavity can be controlled precisely, but the manufacturing complexity increases
Solution Approach 1:
The arcuate ferrule configuration enables self-positioning within the cavity through contact with the cavity walls. The geometry itself provides the alignment function, eliminating the need for additional positioning mechanisms or complex adjustment procedures
Data Source
AI summary
A connector comprising a first outer housing defining at least one cavity, the cavity being cylindrical, a first insert disposed in the cavity, the first insert comprising at least a first housing, the housing being cylindrical, a first ferrule in the first housing, the first ferrule configured with arcuate sides to be received in the cavity, the first ferule comprising an end face, at least one alignment hole for receiving an alignment pin defined in the end face, and at least one fiber-receiving channel for receiving an optical fiber, an optical fiber disposed in the fiber-receiving channel of the first ferrule.