Deformable Plastic Cover for Multi-Optical Fiber Alignment
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Solution Overview
Problem
Multi-optical fiber connector modules face challenges in achieving precise optical alignment due to manufacturing tolerances, leading to unacceptable optical losses and signal degradation, especially when the ends of optical fibers are not precisely positioned, resulting in high bit error rates.
Innovation Solution
A multi-optical fiber connector module utilizing an unfilled plastic cover with deformable features that permanently deform around unjacketed optical fibers, securing them between V-shaped grooves for precise location and alignment, combined with adhesive material to fix the fibers in place and prevent internal reflections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional rigid alignment features are used, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent changes the physical state and mechanical properties of the alignment features by using deformable material with durometer between 20-70. This allows the features to transition from a rigid manufacturing constraint to a compliant functional element that deforms under fiber insertion force to achieve precise optical alignment, resolving the contradiction between precision and complexity
Solution Approach 2:
The patent employs composite construction by combining unfilled plastic material for the cover body with deformable features having different mechanical properties (durometer 20-70). This material composite allows the cover to provide both structural support and compliant alignment functionality, achieving precise optical alignment without complex rigid feature sets
2Manufacturing precision
If tight manufacturing tolerances are enforced, then optical alignment precision is improved, but productivity and manufacturing cost worsen
Solution Approach 1:
The deformable alignment features perform self-alignment by deforming in response to fiber insertion forces. The features automatically adjust their position and shape to achieve optimal optical alignment without requiring precision control during assembly, enabling manufacturing with relaxed tolerances and higher throughput
Solution Approach 2:
The patent introduces dynamic compliance to the alignment system through deformable features that can change shape during fiber insertion. This dynamic adaptation allows the system to compensate for manufacturing variations in real-time, achieving precise fiber positioning without enforcing tight manufacturing tolerances
3Ease of operation
If deformable features are used to improve alignment, then ease of operation is improved, but manufacturing precision may worsen due to material compliance
Solution Approach 1:
The patent carefully selects and controls the durometer parameter of the deformable features (between 20-70) to achieve the optimal balance between compliance for easy insertion and rigidity for precise positioning. This parameter optimization ensures the features deform sufficiently to facilitate insertion but maintain enough stiffness to achieve precise fiber location
Solution Approach 2:
The deformable features are strategically positioned at specific locations where fiber contact is required, while the rest of the cover maintains its structural integrity. This localized deformation capability allows easy fiber insertion at contact points without compromising the overall precision and stability of the fiber positioning system
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
Ensures precise optical alignment and high coupling efficiency by securely pinning the optical fibers between deformable features and grooves, reducing signal degradation and bit error rates while maintaining a thin and cost-effective design.
Implementation Method 1
an unfilled plastic molded part having a plurality of deformable features disposed on a lower surface thereof... the deformable features permanently deform about the respective unjacketed portions of the optical fibers
Data Source
AI summary
A multi-optical fiber connector module is provided with an unfilled plastic cover that is used to secure the ends of a plurality of optical fibers at precise locations within the connector modules. The cover has deformable features that permanently deform when the cover is secured to a housing of the connector module. The permanent deformations are caused by forces that are exerted on the deformable features by respective unjacketed optical fibers when the cover is secured to the module housing. When the features deform, they partially wrap about the respective unjacketed optical fibers such that the respective fibers are pinned between the respective deformed features and the respective V-shaped grooves of the module housing. This contact between the deformed features, the respective unjacketed optical fibers and the respective V-shaped grooves maintains the respective unjacketed optical fibers in precise locations along respective optical pathways of the connector module.