Deflectable Ferrule Optical Connector Assembly
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Solution Overview
Problem
Existing optical connectors are often complex and unreliable over time, failing to provide a simple, cost-effective, and robust solution for easy assembly, testing, and operation while effectively handling misalignment and external influences like vibrations.
Innovation Solution
The optical connector assembly features a plug and socket with deflectable ferrules supported by springs and deformable holding sleeves, utilizing alignment features for coarse and fine alignment, and a locking mechanism for secure connection, allowing for axial and lateral movement to absorb external stresses and improve signal propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If floating ferrule mechanisms are used to compensate misalignment, then alignment reliability is improved, but device complexity increases
Solution Approach 1:
The alignment function is segmented into two distinct mechanisms: coarse alignment features (alignment grooves and protrusions) for initial positioning, and fine alignment features (guiding pins and guiding holes) for precision adjustment. This segmentation allows each mechanism to be optimized independently while reducing overall system complexity compared to a single floating ferrule system.
Solution Approach 2:
The patent introduces an alignment sleeve as an intermediary component between the ferrule and housing. The sleeve provides a simplified interface that enables both coarse and fine alignment functions without requiring complex floating ferrule mechanisms, thereby reducing device complexity while maintaining alignment reliability.
2Reliability
If deformable holding sleeves are used to absorb external stresses, then reliability under vibration is improved, but manufacturing complexity increases
Solution Approach 1:
The holding sleeve's material properties are optimized to provide controlled deformability. By selecting materials with appropriate elastic moduli and damping characteristics, the sleeve can absorb vibrations and external stresses effectively. This parameter-based approach allows standard manufacturing processes to be used while achieving the desired shock absorption performance.
Solution Approach 2:
The holding sleeve is made from composite materials or materials with specific viscoelastic properties that combine structural support with vibration damping capabilities. This allows the single component to simultaneously provide mechanical support and absorb external stresses, eliminating the need for separate damping components and simplifying manufacturing.
3Manufacturing precision
If dual alignment features (coarse and fine) are implemented, then alignment precision is improved, but device complexity increases
Solution Approach 1:
The alignment function is segmented into two distinct mechanisms: coarse alignment features (alignment grooves and protrusions) for initial positioning, and fine alignment features (guiding pins and guiding holes) for precision adjustment. This segmentation allows each mechanism to be optimized independently while reducing overall system complexity compared to a single floating ferrule system.
Solution Approach 2:
The coarse alignment features perform the preliminary action of bringing the ferrules into approximate alignment before the fine alignment features engage. This preliminary positioning reduces the tolerance requirements for the fine alignment features, allowing them to be simpler in design while still achieving high precision, thereby reducing overall device complexity.
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 design results in a reliable, high-channel-density connector that is easy to assemble and operate, providing rapid connection and improved signal transmission by effectively managing misalignment and external influences.
Implementation Method 1
a first ferrule (7) arranged displaceable in axial direction against the force of a first spring (9)
Implementation Method 2
deformable holding sleeves, utilizing alignment features for coarse and fine alignment, and a locking mechanism for secure connection, allowing for axial and lateral movement to absorb external stresses
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
An optical connector assembly (1) according to the invention in general comprises a plug (2) and a socket (3) which are interconnectable to each other in an axial direction (x). The plug (2) comprises a plug housing (5) in which a first ferrule (7) is arranged and the socket (3) comprises a socket housing (20), in which a second ferrule (23) is arranged. At least one of the ferrules (7, 23) is arranged deflectable in the axial direction (x) against the force of a spring (9). At least one of the ferrules (7, 23) is arranged deflectable in a lateral direction (y, z) with respect to the axial direction.