Expanded Beam Fiber Optic Array Connector
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Solution Overview
Problem
Existing expanded beam multi-fiber connectors face manufacturing difficulties due to precision molding requirements, signal attenuation issues from integrally molded lenses, and thermal expansion problems, leading to reduced strength and increased attenuation in communication systems.
Innovation Solution
Customizing lenses for specific light transmittance or reception tasks within the connector, using separate parts for transmit and receive channels, and employing materials like fused silica or polycarbonate for improved thermal expansion characteristics, while maintaining assembly efficiency through reduced assembly time and labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If lenses are integrally molded with the frame, then assembly time and labor are reduced, but manufacturing complexity and precision requirements increase
Solution Approach 1:
The patent combines the frame and lenses into a single integrally molded component, eliminating the need for separate assembly steps. The mold includes both the frame cavity and lens cavities, allowing simultaneous formation of both components in one molding cycle, thus reducing assembly time and labor while managing manufacturing complexity through integrated tooling design.
2Adaptability or versatility
If the frame is molded from light-transmitting material, then lens functionality is integrated, but strength and thermal stability decrease
Solution Approach 1:
The patent employs composite material construction where the frame is made from a light-transmitting polymer matrix reinforced with dispersed particles or fillers that enhance mechanical strength and reduce thermal expansion. This composite approach allows the frame to simultaneously provide optical transparency for lens integration and the structural strength required for connector durability.
3Strength
If fillers are added to the polymer for strength, then mechanical properties improve, but light transmission consistency deteriorates
Solution Approach 1:
The patent applies local quality by concentrating fillers or reinforcement materials in specific regions of the frame where mechanical strength is most needed, while maintaining clearer, filler-free zones in areas requiring optimal light transmission. This spatial differentiation of material properties allows the frame to simultaneously achieve both structural integrity and optical consistency without compromise.
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
Enhances the performance of expanded beam multi-fiber connectors by minimizing signal loss and mechanical stress, improving thermal stability, and simplifying manufacturing processes while maintaining the benefits of integrally molded lenses.
Implementation Method 1
a lens 91, such as spherical lenses 91-1 through 91-8 formed of sapphire
Implementation Method 2
a lens 91, such as spherical lenses 91-1 through 91-8 formed of sapphire
Data Source
AI summary
An expanded beam fiber optic array connector includes a ferrule holding ends of optical fibers in a first ordered array. A plurality of lenses packaged into a unitary structure, formed of an optical grade material, different than a material used to form the ferrule, is attached to the ferrule. The lenses are arranged into a second ordered array matching the first ordered array of the ends of the optical fibers. The lenses of the expanded beam connector associated with transmit channels can be constructed with a prescription geared specifically for transmitting light, whereas the lenses of the expanded beam connector associated with receive channels can be constructed with a prescription geared specifically for receiving light.