Blind-mating Optical Ferrule Assemblies with Two-stage Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Blind-mating optical ferrule assemblies in electronic module enclosures require large alignment features with tight tolerances, which increases space requirements and manufacturing costs, and poses a risk of damaging components during alignment.
Innovation Solution
Employing semi-final alignment features with a coarse tolerance followed by final alignment features with a tight tolerance in optical blind-mate connector adapters, allowing for easier and safer precision alignment of optical ferrules without relying on human vision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If large alignment features with tight tolerances are used for blind-mating optical ferrule assemblies, then alignment precision is improved, but space requirements and manufacturing costs increase
Solution Approach 1:
The alignment process is divided into two distinct stages: first alignment features with coarse tolerance perform initial alignment, and second alignment features with tight tolerance perform final precision alignment. This segmentation allows each stage to use appropriately sized features, reducing the need for large space-consuming tight-tolerance features throughout the entire process.
Solution Approach 2:
The first alignment features perform preliminary alignment at a coarse tolerance level before the final alignment occurs. This preliminary action brings the optical ferrule assemblies into approximate alignment, reducing the burden on the second alignment features and allowing them to be smaller and less complex.
2Manufacturing precision
If large alignment features with tight tolerances are used for blind-mating optical ferrule assemblies, then alignment precision is improved, but manufacturing costs increase
Solution Approach 1:
Manufacturing costs are reduced by segmenting the alignment features into two groups with different tolerance requirements. The first alignment features can be manufactured with standard, lower-cost tolerances, while only the critical second alignment features require expensive tight-tolerance manufacturing processes.
Solution Approach 2:
Different parts of the alignment system have different quality requirements. The first alignment features use coarse tolerance appropriate for their function, while only the local area of the second alignment features requires tight tolerance. This local quality approach reduces overall manufacturing costs by applying high-precision manufacturing only where absolutely necessary.
3Manufacturing precision
If large alignment features with tight tolerances are used for blind-mating optical ferrule assemblies, then alignment precision is improved, but the risk of damaging components during alignment increases
Solution Approach 1:
The first alignment features with coarse tolerance act as a cushioning mechanism that absorbs alignment errors and prevents direct contact between the more vulnerable second alignment features and misaligned components. This beforehand cushioning reduces the risk of damage during the blind-mating process.
Solution Approach 2:
The first alignment features perform preliminary alignment that gently guides the optical ferrule assemblies into approximate position before the second alignment features engage. This preliminary action prevents forceful impacts that could damage components, as the coarse-tolerance features can accommodate larger misalignments without causing damage.
Data Source
AI summary
Example implementations relate to blind-mating optical ferrule assemblies. For example, an apparatus to blind-mate optical ferrule assemblies can comprise a first optical ferrule assembly including a ferrule housing and a ferrule disposed at least in part within the ferrule housing, a semi-final alignment pin and a semi-final alignment hole disposed on the first optical ferrule assembly to align the first optical ferrule assembly with a second optical ferrule assembly, and a final alignment pin and a final alignment hole disposed on the first optical ferrule assembly to further align the first optical ferrule assembly to the second optical ferrule assembly.