Ferrule With Integrated Fiber Alignment For Optical Connectors
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Solution Overview
Problem
Existing optical fiber connector systems face challenges in aligning ferrule-less optical fiber systems with ferruled systems, particularly due to the need for precise polishing of ferrule mating faces and the bulk of ferrules, which increases costs and complicates fiber density, and there is a need for a reliable method to connect these systems effectively.
Innovation Solution
A device and method that utilize a ferrule with a fiber stub and an alignment portion featuring an elastic element, allowing the bare end of a ferrule-less optical fiber to be aligned with a ferrule, using a common channel that opens against an elastic force, enabling alignment with ferruled systems without the need for precise polishing and minimizing space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ferrule is used to hold and align optical fibers, then fiber alignment and protection are improved, but the bulk of the ferrule increases connector size and reduces fiber density
Solution Approach 1:
The invention extracts the alignment function from the traditional ferrule structure. Instead of using a bulky ferrule to hold and align multiple fibers, the patent uses a ferrule-less design where individual fiber stubs are directly positioned in alignment grooves within the connector body, eliminating the need for a separate ferrule component and reducing overall connector volume.
Solution Approach 2:
The connector is segmented into distinct functional zones: alignment grooves for positioning fiber stubs, sealing regions for environmental protection, and connection interfaces. This segmentation allows each component to perform its specific function efficiently without requiring the bulk of a traditional ferrule structure.
2Strength
If a ferrule is used to provide structural support and protection, then fiber end protection is improved, but the need for precise polishing of the mating face increases manufacturing complexity and cost
Solution Approach 1:
The invention removes the ferrule component entirely, extracting the protection function to the connector body itself through integrated sealing elements and alignment grooves. This eliminates the need for separate ferrule polishing operations, as the alignment surfaces are formed directly in the connector housing through molding or machining processes.
Solution Approach 2:
The fiber stubs are designed as disposable or replaceable components that can be easily installed and replaced without requiring precision polishing. The alignment grooves provide sufficient alignment accuracy through their geometric design, eliminating the need for costly and time-consuming polishing operations.
3Ease of operation
If a ferrule is used to accommodate multiple fibers, then fiber manageability is improved, but the bulk of the ferrule negatively affects the minimum center line distance between fibers
Solution Approach 1:
The invention extracts the fiber holding function from the ferrule and implements it through individual fiber stubs positioned in alignment grooves within the connector body. This allows for tighter spacing between fibers since the alignment is achieved through precision-machined grooves rather than through ferrule geometry, reducing the minimum center line distance.
4Volume of moving object
If ferrule-less connectors are used to reduce bulk and cost, then connector size and manufacturing cost are reduced, but the ability to connect to ferruled systems is lost
Solution Approach 1:
The invention uses fiber stubs as intermediary elements that bridge ferrule-less and ferruled systems. The fiber stubs can be inserted into traditional ferrule connectors, allowing ferrule-less connectors to interface with ferruled systems. The stubs act as adapters, enabling compatibility without requiring the bulk of a full ferrule structure in the ferrule-less connector.
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 provides a reliable, self-aligning mechanism for connecting ferrule-less optical fibers to ferruled systems, reducing the risk of fiber damage, allowing multiple connections and disconnections, and improving optical coupling efficiency by minimizing Fresnel reflections with index matching materials and sealing elements.
Implementation Method 1
said alignment portion comprises an elastic element adapted for opening said common channel, against a force exerted by said elastic element, by a force exerted by insertion of the bare end of the optical fiber in said common channel
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
A device (1), and a corresponding method, for aligning an optical fiber, the device comprising a ferrule (10) and an alignment portion (4) for receiving a bare end (12) of the optical fiber, wherein the ferrule (10) and the alignment portion (4) have a common channel (9), the ferrule comprising in the common channel (9) a fiber stub (15) for being aligned with the bare end (12) of the optical fiber, and wherein the alignment portion (4) comprises an elastic element (2) adapted for opening the common channel (9), against a force exerted by the elastic element (2), by a force exerted by insertion of the bare end (12) of the optical fiber in the common channel (9).