Dual-Cavity Fiber Optic Module for High-Density WDM Assembly
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Solution Overview
Problem
The construction of WDM cassettes is labor-intensive and time-consuming, with high risks of damaging optical fibers and forming defective splices, leading to low first pass yield and difficulties in rework due to unorganized excess fiber lengths and lack of fiber routing fixtures.
Innovation Solution
A fiber optic connection module with dual cavities separated by a floor, featuring fiber guide members and lateral openings for inter-cavity routing, allowing for increased component density and flexibility in optical component assembly and interconnection, along with mechanical interlocking features for module assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If single cavity modules are used, then manufacturing is simpler, but component density is lower
Solution Approach 1:
The module is divided into two separate cavities (first cavity and second cavity) within a single housing, allowing independent placement of optical components in each cavity. This segmentation enables doubled component density while maintaining manageable complexity through modular internal organization.
Solution Approach 2:
The invention transitions from a single-plane (2D) component arrangement to a multi-level (3D) arrangement by stacking two cavities vertically within the same housing footprint. This dimensional change doubles the effective component capacity without increasing the horizontal space occupied.
2Ease of repair
If traditional fiber routing methods are used, then fiber management is simpler, but rework is more difficult
Solution Approach 1:
Excess fiber length is intentionally managed and routed through designated paths during initial assembly, with fibers extending from both cavities to accessible exterior locations. This preliminary organization of fiber routing enables future rework and reconfiguration without requiring disassembly of the entire module.
Solution Approach 2:
The housing structure acts as an intermediary that provides dedicated fiber routing paths and exterior access points, mediating between the internal optical components and external fiber management systems. This intermediary structure simplifies rework by providing controlled access to fibers without direct manipulation of internal components.
3Quantity of substance
If more optical components are placed in a single cavity, then component density increases, but fiber routing becomes more complex and error-prone
Solution Approach 1:
By dividing components into two separate cavities, each cavity contains a manageable subset of optical components and associated fibers. This segmentation reduces the complexity of fiber routing within each cavity, lowering the risk of splice errors and improving manufacturing precision while achieving overall high component density through the combined capacity of both cavities.
Data Source
AI summary
A fiber optic connection module includes a body structure defining upper and lower cavities separated by a floor, with each cavity being configured to receive multiple optical components (e.g., three-port optical components) and multiple splices. Sidewalls of the body structure include upper peripheral sidewall portions that laterally bound the upper cavity, and lower peripheral sidewall portions that laterally bound the lower cavity. In each of the respective cavities, multiple fiber guide members project from the floor into the cavity, and are configured to retain a plurality of optical fibers between the fiber guide members and peripheral sidewall portions. Openings in the floor permit inter-cavity fiber routing within a module, while lateral openings in sidewalls of modules permit optical fibers to be routed between modules when in a side-by side configuration. A fiber optic apparatus including multiple cassettes and multiple fiber optic connection modules therein may support a density of 108 or 144 three-port optical components per U-space of a chassis arrangeable in an equipment rack.