Ferrule-Less Optical Fiber Connection System
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Solution Overview
Problem
Conventional optical fiber connectors face high optical loss and space limitations, making them unsuitable for high-bandwidth applications like 100G and 400G transmission rates, and existing interconnection methods like fusion splicing and mechanical splices have drawbacks such as high power requirements and structural integrity issues.
Innovation Solution
A ferrule-less optical fiber connection system using bare fiber holders with splice elements featuring alternating alignment and clamping channels, which securely interconnect optical fibers with minimal loss and structural integrity, employing a clamping mechanism that aligns and holds fibers end-to-end without the need for index matching gels or adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional ferrule type connectors are used, then ease of reconfiguration is improved, but optical loss increases (0.2-0.3 dB for single fiber, 0.35-0.7 dB for multi-fiber)
Solution Approach 1:
The patent removes the ferrule component entirely from the connector design, extracting it from the conventional connector structure. This allows the optical fiber ends to be directly aligned and connected without the ferrule intermediary, reducing the sources of optical loss while maintaining ease of reconfiguration through the simplified direct-connect design.
Solution Approach 2:
The patent introduces an alignment channel structure as an intermediary element that guides and positions the optical fibers during connection. This alignment channel acts as a mediator to ensure precise end-to-end alignment of fiber cores, achieving low optical loss without requiring traditional ferrules or complex multi-component connectors.
2Loss of energy
If fusion splicing is used, then optical loss is reduced to permanent reliable splices, but handling complexity and space requirements increase (require separate splice rack)
Solution Approach 1:
The patent divides the fiber connection function into two separate but complementary components: a first connector with alignment channels for one fiber array and a second connector with corresponding alignment channels for another fiber array. When mated together, these segmented connectors create the complete connection, allowing fusion-like performance without requiring permanent splicing equipment or complex handling procedures.
Solution Approach 2:
The patent creates a reusable connector design that can be manufactured and installed without requiring permanent fusion splicing equipment. The alignment channel structure replicates the precise alignment capability of fusion splices in a mechanical connector format, eliminating the need for separate splice racks while maintaining low optical loss.
3Loss of energy
If traditional gel type mechanical splices are used, then optical loss is reduced (better than connectors, approaching fusion splices), but structural integrity is lost (index matching gels are not solid materials)
Solution Approach 1:
The patent applies different structural characteristics to different regions of the connector: the alignment channels provide precise local alignment of fiber cores, while the clamping mechanism provides distributed mechanical strength. This local differentiation allows the connector to achieve both low optical loss through precise alignment and high structural integrity through the solid clamping structure, eliminating the need for gel materials.
4Productivity
If multi-fiber connectors are used, then bandwidth capacity is improved, but space required increases (limits interconnection density)
Solution Approach 1:
The patent transitions from traditional planar multi-fiber connector layouts to a three-dimensional stacked configuration where multiple fiber arrays are vertically stacked and connected through precise alignment channels. This dimensional change allows high-bandwidth capacity to be achieved in a compact footprint, increasing interconnection density by utilizing the vertical space rather than expanding horizontally.
Data Source
AI summary
An optical fiber connection system (100) for connecting a plurality of optical fibers is described. The connection system comprises a first bare fiber holder (120) comprising a first splice element (160) and a second bare fiber holder (120′) comprising a second splice element (160′). Each of the first and second splice elements (160,160′) comprises a splice body (161) having a first end (160a) and a second end (160b) and a plurality of alternating alignment and clamping channels (165,167) formed in a top surface (161b) of the splice body (161) that extend from the first end to the second end of the splice body. When the first and second bare fiber holders (120,120′) are mated, at least a portion of the alignment channels (165) of the first splice element (160) overlap a portion of the clamping channels (167) in the second splice element (160′) and at least a portion of the clamping channels (167) of the first splice element (160) overlap a portion of the alignment channels (165) of the second splice element (160′) to hold the first and second optical fibers in end to end alignment.