Ferrule-less Fiber Optic Connector Alignment
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Solution Overview
Problem
Fiber optic connectors with ferrules face challenges in alignment and signal interference due to the presence of metal components, and existing ferrule-less connectors lack efficient mechanisms for securing and aligning optical fibers without ferrules.
Innovation Solution
The development of ferrule-less fiber optic connectors with flexible latches and buckling chambers that securely hold optical fibers without ferrules, using elastomeric alignment structures and non-gaseous fluids for protection and alignment, allowing for precise spacing and alignment of optical fibers within a connector body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If ferrules are used to support optical fibers, then alignment precision is improved, but signal interference and device complexity increase due to metal components
Solution Approach 1:
The patent removes ferrules (metal components) from the fiber optic connector system entirely. Instead of using ferrules to support and align optical fibers, the invention uses a dust cap with internal alignment features and flexible latches that secure fibers without metal ferrules, thereby eliminating signal interference while maintaining alignment precision
Solution Approach 2:
The dust cap serves as an intermediary structure that provides alignment functionality previously performed by ferrules. The dust cap includes alignment features such as ridges or protrusions that interface with corresponding features in the connector body, enabling precise fiber alignment without requiring metal ferrule components
2Object-generated harmful factors
If ferrule-less design is used, then signal interference is reduced, but fiber alignment and security become more difficult
Solution Approach 1:
The dust cap acts as an intermediary alignment mechanism that guides and positions optical fibers during insertion. It includes internal alignment features such as ridges, protrusions, or shaped cavities that interface with corresponding features in the connector body, enabling precise fiber alignment without metal ferrules
Solution Approach 2:
The flexible latches automatically engage with the connector body when the dust cap is inserted, securing the optical fibers in place without requiring additional manual alignment steps. The latches self-adjust to accommodate fiber positioning while maintaining secure connection
3Device complexity
If optical fibers are secured without ferrules, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The dust cap is pre-formed with precise internal alignment features such as ridges, protrusions, or shaped cavities during manufacturing. These pre-configured alignment features ensure that when the dust cap is inserted into the connector body, the optical fibers are automatically positioned with the required precision, transferring the manufacturing precision requirement to the dust cap fabrication process rather than final assembly
Solution Approach 2:
The invention specifies precise geometric parameters for the dust cap alignment features (such as ridge dimensions, cavity shapes, and positional tolerances) that, when manufactured within controlled tolerances, guarantee proper fiber alignment. This approach manages manufacturing precision through controlled parameters in a simplified structure
Data Source
AI summary
The present disclosure relates to a ferrule-less fiber optic connector including a connector body having a front end. The ferrule-less fiber optic connector can include a plurality of optical fibers that extend through the connector body. The optical fibers can have having free end portions at the front end of the connector body that are not supported by a ferrule or by ferrules. In one example, the ferrule-less fiber optic connector can be a duplex fiber optic connector. Transceiver modules and components are also disclosed.