Blind Mating Multi-Optical Fiber Connector Modules

Solution Overview

Problem

Current multi-optical fiber connector modules require precise mechanical tolerances for alignment, leading to increased manufacturing costs and complexity, especially when multiple modules need to be simultaneously aligned, which is challenging and time-consuming.

Innovation Solution

The system employs passive coarse and fine alignment features on sockets and connector modules that allow for blind mating, enabling multiple modules to be simultaneously aligned and mated without the need for individual optical cable interconnections, using spring-mounted sockets with tapered alignment features to achieve precise optical alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If very tight mechanical tolerances are used to ensure precise optical alignment, then optical alignment precision is improved, but manufacturing costs increase and yield decreases

Engineering Contradiction:

Improveoptical alignment precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The alignment system is segmented into two distinct functional levels: passive coarse alignment features (key/keyway structures) that provide initial mechanical guidance and positioning, and passive fine alignment features (tapered cylindrical features) that provide precise optical alignment. This segmentation allows each level to operate within relaxed tolerance ranges while achieving cumulative sub-mil optical alignment precision, thereby reducing manufacturing costs and improving yield.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If very tight mechanical tolerances are used to ensure precise optical alignment, then optical alignment precision is improved, but manufacturing yield decreases

Engineering Contradiction:

Improveoptical alignment precisionVSAvoidmanufacturing yield

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The alignment system is segmented into two distinct functional levels: passive coarse alignment features (key/keyway structures) that provide initial mechanical guidance and positioning, and passive fine alignment features (tapered cylindrical features) that provide precise optical alignment. This segmentation allows each level to operate within relaxed tolerance ranges while achieving cumulative sub-mil optical alignment precision, thereby reducing manufacturing costs and improving yield.

Inventive Principle:

Principle #1Segmentation

3Productivity

If passive alignment features are used for simultaneous blind mating of multiple connector modules, then alignment speed and efficiency are improved, but alignment precision may be compromised

Engineering Contradiction:

Improvealignment efficiencyVSAvoidoptical alignment precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The alignment system is segmented into two distinct functional levels: passive coarse alignment features (key/keyway structures) that provide initial mechanical guidance and positioning, and passive fine alignment features (tapered cylindrical features) that provide precise optical alignment. This segmentation allows each level to operate within relaxed tolerance ranges while achieving cumulative sub-mil optical alignment precision, thereby reducing manufacturing costs and improving yield.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The passive coarse alignment features perform the preliminary action of bringing the connector modules into approximate alignment before the fine alignment features engage. This preliminary positioning ensures that the tapered cylindrical fine alignment features can then achieve precise optical alignment through their self-correcting geometry, enabling simultaneous blind mating of multiple modules with sub-mil precision.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS9140862B2Methods, apparatuses and systems for blind mating multi-optical fiber connector modules

Publication Date: 2015.09.22 AVAGO TECHNOLOGIES INTERNATIONAL SALES PTE LTD

AI summary

Apparatuses, systems and methods are provided that enable N female multi-optical fiber connector modules disposed on a first structure to be simultaneously blind mated with N male multi-optical fiber connector modules disposed on a second structure, where N is a positive integer that is equal to or greater than one. Enabling the male and female multi-optical fiber connector modules to blind mate with one another obviates the need to individually interconnect the modules with optical cables. Each module is mounted on either a male or female socket, which, in turn, is mounted on the first or second structure. The first structure may be, for example, a rack having at least one slot configured to receive a server box, in which case the second structure is the server box itself.