Detachable Multi-Ferrule Connectors for High Fiber Alignment
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Solution Overview
Problem
Conventional connector termination technology is limited to about 32 fibers per connector, and there is a need for a high fiber count termination process that enables connections of more than 144 fibers in a small footprint while maintaining low insertion loss and cost per fiber termination.
Innovation Solution
A matched pair detachable connector design with a ferrule and keyway configuration that maintains optical fiber alignment and ferrule alignment during assembly, using a sleeve and key to limit rotational movement, and a spring mechanism to ensure axial alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional connector termination technology is used, then each connector can handle about 32 fibers, but the number of connectors required increases significantly for high fiber count applications
Solution Approach 1:
The patent combines multiple ferrules (each handling 32 fibers) into a single connector assembly, creating a 144-fiber connector by merging four ferrules. This reduces the total number of connectors needed in the system while maintaining the proven 32-fiber-per-ferrule termination quality.
Solution Approach 2:
The connector is segmented into multiple ferrules that can be independently terminated and then assembled into a unified connector. This allows factory termination of individual ferrules to be combined into high-density connectors, enabling scalable fiber count configurations.
2Loss of time
If the number of connectors is reduced for high fiber count applications, then fewer matings are required, but maintaining precise alignment becomes more difficult
Solution Approach 1:
The patent introduces an adapter as an intermediary component that receives multiple ferrules and provides a unified interface. The adapter contains alignment features and registration mechanisms that ensure precise positioning of multiple ferrules relative to each other, maintaining alignment precision while enabling high fiber count connections.
Solution Approach 2:
Individual ferrules are pre-terminated with connectors in the factory with precise alignment features already in place. These pre-terminated ferrule assemblies are then systematically assembled into the multi-ferrule connector configuration, with alignment established during the assembly process through mechanical registration features.
3Quantity of substance
If high fiber count connectors are developed, then fewer connectors are needed, but the cost per fiber termination increases due to reduced yield
Solution Approach 1:
The manufacturing process is segmented into terminating individual ferrules (each handling 32 fibers) separately and then assembling them into multi-ferrule connectors. This modular approach maintains high yield rates for individual ferrule terminations while achieving high overall fiber counts, avoiding the yield penalties associated with attempting to terminate all 144 fibers in a single connector.
Solution Approach 2:
Multiple successfully terminated ferrules are combined into a single connector assembly, achieving high fiber count capability while maintaining the cost efficiency of individual ferrule termination processes. The assembly process leverages standard化的 ferrule components to control overall manufacturing cost.
Data Source
AI summary
The present disclosure relates to a matched pair detachable connector for high fiber count applications where the configuration of the connector maintains optical fiber alignment and ferrule alignment during assembly of the connector.