Expanded Beam Fiber Optic Connector With Recessed Lens
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Solution Overview
Problem
Fiber optic connectors in harsh environments are susceptible to damage from vibration, dirt, and dust, leading to signal loss and inconsistent performance due to physical contact and design inefficiencies.
Innovation Solution
A fiber optic terminus with a recessed lens and epoxy attachment within a ferrule, featuring an inspection slot and retaining features like o-rings or metal sleeves, converts physical contact connectors to expanded beam connectors, reducing physical contact and enhancing durability and maintainability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a typical fiber optic termination with physical contact is used, then connection stability is achieved, but susceptibility to vibration damage and dirt accumulation increases
Solution Approach 1:
The patent introduces an expanded beam optical system with lenses as an intermediary between the fiber optic cable and the connector interface. Instead of direct physical contact between fiber ends, the invention uses lens elements that create an expanded light path, allowing the optical signal to transmit without the fibers needing to be in direct contact. This intermediary optical system protects against vibration damage and reduces sensitivity to dirt and dust accumulation at the connection interface.
Solution Approach 2:
The invention replaces the mechanical physical contact system with an optical expanded beam system. Rather than relying on mechanical alignment and direct fiber-to-fiber contact, the patent uses lens elements to expand and transmit the optical beam through air or other media without requiring tight mechanical tolerances or direct contact. This substitution eliminates the mechanical wear and vibration sensitivity inherent in traditional physical contact connectors.
2Reliability
If physical contact connectors are used in harsh environments, then signal transmission is maintained, but signal loss from dust and debris increases
Solution Approach 1:
The patent transitions from a one-dimensional direct fiber-to-fiber contact interface to a three-dimensional expanded beam optical path. By using lens elements to expand the light beam and create a larger transmission path through air or other media, the invention reduces the impact of dust and debris that would otherwise block the narrow direct contact interface. The expanded beam geometry allows the optical signal to clear obstacles more effectively.
3Ease of manufacture
If traditional fiber optic terminations are used, then manufacturing simplicity is maintained, but ease of repair and maintenance decreases
Solution Approach 1:
The patent segments the fiber optic connection system into modular components: the fiber optic cable with its termination, the expanded beam connector with lens elements, and the receiving structure. This segmentation allows individual components to be manufactured separately using standardized processes and enables easy replacement of specific components (such as lens elements or connector housings) without requiring replacement of the entire assembly, thereby improving ease of repair and maintenance.
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
The solution significantly reduces signal attenuation from dust and debris, improves connector reliability in harsh environments by minimizing physical contact, and allows for easier maintenance and repair of individual channels, maintaining consistent performance over time.
Implementation Method 1
A lens is attached to an optical fiber and ferrule structure by an epoxy
Data Source
AI summary
A terminus for a fiber optic cable includes a ferrule. An optic fiber of the cable passes through a central bore of the ferrule and is attached to a lens seated in a conical or cylindrical seat formed in an end surface of the ferrule by an epoxy. Preferably, the seat permits the lens to be recessed below the end surface of the ferrule. An inspection slot may be formed through the seat to allow a technician to inspect the state of the epoxy attachment. The ferrule may also include retaining features, such as an o-ring encircling a groove in the outer circumference of the ferrule or a metal sleeve crimped or otherwise attached to the ferrule to permit the ferrule to be easily attached to a cable retention sleeve, connector body or similar structure.