Expanded Beam Fiber Optic Connector Single-Bore Alignment
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Solution Overview
Problem
Expanded beam fibre optic connectors face challenges in precise alignment of optical fibres and lenses, leading to light losses, especially in harsh environments, and require complex manufacturing processes and specialized tools.
Innovation Solution
The design features a single-bore insert with a press-fit ceramic sleeve and lens configuration, allowing for simplified alignment and manufacturing, along with a cable management system that prevents fibre twisting using a secure engagement mechanism, enabling easy field assembly and maintenance without specialized tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional multi-bore inserts are used for alignment, then alignment precision between ferrule and lens is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the alignment function and the positioning function into a single bore structure. The insert has only one bore that receives both the ferrule and the lens, eliminating the need for separate alignment bores. This simplifies the insert structure while maintaining alignment precision through the use of a single reference axis.
Solution Approach 2:
The single bore in the insert serves multiple functions: it provides the reference axis for alignment, positions both the ferrule and lens, and eliminates the need for separate alignment features. This multi-functional design reduces manufacturing steps and insert complexity while achieving the required alignment precision.
2Manufacturing precision
If specialized precision tools are used for assembly, then alignment precision is improved, but ease of operation deteriorates
Solution Approach 1:
The connector components are designed to self-align during assembly. The single bore insert with its specific dimensional tolerances allows the ferrule and lens to automatically position themselves correctly when inserted, eliminating the need for specialized alignment tools or complex adjustment procedures in the field.
Solution Approach 2:
The patent specifies precise dimensional parameters for the bore diameter, ferrule outer diameter, and lens outer diameter that enable interference fit and automatic alignment. By controlling these dimensional parameters within tight tolerances, the design achieves precise alignment through simple insertion without requiring specialized tools.
3Ease of operation
If ferrule and lens are separated with butt joints, then alignment is assisted, but light loss increases
Solution Approach 1:
The patent eliminates the butt joint by merging the ferrule and lens into direct contact within the single bore. The ferrule rear end contacts the lens directly, removing the intermediate air gap or coupling point that causes light loss, while the single bore structure provides the necessary alignment guidance.
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
This solution minimizes light losses by ensuring precise alignment and secure contact between optical components, reduces manufacturing complexity, and prevents fibre twisting, enhancing the reliability and usability of fibre optic connectors in harsh environments.
Implementation Method 1
each sleeve and each lens is held in a press fit engagement
Data Source
AI summary
An expanded beam fibre optic connector and a cable management system for an expanded beam fibre optic connector. The expanded beam fibre optic connector comprises an insert comprising one or more cylindrical insert bores each having an insert bore diameter along a length of the insert bore, and a sleeve and a lens disposed in each insert bore. The single diameter insert bore simplifies alignment between the sleeve(s) and the lens(es). The cable management system comprises an inner housing and an outer housing, an insert configured to hold a termination of one or more optical fibres of an optical fibre cable, and an inner crimp configured to grip an outer jacket of the optical fibre cable. The inner crimp and the inner housing comprise engagement surfaces configured to engage with one another and thereby prevent rotation of the inner housing relative to the optical fibre cable to prevent twisting.