Ferrule-less Fiber Optic Connection Modules

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Solution Overview

Problem

Ferruled fiber optic connectors add significant cost, complexity, and vulnerability to contamination, while occupying more space and requiring time-consuming processing, which hampers the ease of manufacturing and installation of fiber optic network components.

Innovation Solution

The use of ferrule-less fiber optic connection technology with demateable connection locations that include fiber alignment devices for coaxially aligning non-ferrulized optical fibers, utilizing structures such as elastic cantilevers, micro bores, and index matching gel to ensure effective optical coupling and reduce contamination risks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If ferruled fiber optic connectors are used, then alignment precision is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvealignment precisionVSAvoidconnector complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent removes the ferrule component from the connector design, extracting only the essential function of fiber alignment and connection. This eliminates the complex ferrule assembly while maintaining alignment precision through alternative means such as precision-machined alignment features directly in the connector housing or simplified alignment mechanisms.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention employs simpler, more cost-effective connector designs that can be manufactured at lower cost and potentially replaced more easily. The ferrule-less design uses less expensive materials and manufacturing processes while achieving sufficient alignment precision for practical applications.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Manufacturing precision

If ferruled fiber optic connectors are used, then alignment precision is improved, but manufacturing time increases

Engineering Contradiction:

Improvealignment precisionVSAvoidmanufacturing speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

By removing the ferrule component, the manufacturing process is simplified and accelerated. The ferrule-less design eliminates steps such as ferrule installation, positioning, and securing, allowing for faster assembly and reduced manufacturing cycle times while maintaining adequate alignment precision.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The connector design incorporates pre-formed alignment features or pre-assembled components that eliminate the need for time-consuming alignment adjustments during final assembly. Alignment precision is built into the design rather than requiring complex adjustment procedures.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If ferruled fiber optic connectors are used, then connection reliability is improved, but vulnerability to contamination increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidcontamination vulnerability

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent removes the ferrule component that creates contamination pockets and difficult-to-clean surfaces. The ferrule-less design exposes fewer hidden surfaces where contaminants can accumulate, making the connector easier to clean and less susceptible to contamination-related failures.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention may incorporate protective coatings or thin-film layers on the connector surfaces that provide contamination resistance while maintaining optical performance. These coatings can be applied as simple post-manufacturing steps and enhance resistance to environmental contaminants.

Inventive Principle:

Principle #30Flexible shells and thin films

4Manufacturing precision

If ferruled fiber optic connectors are used, then alignment precision is improved, but physical space requirements increase

Engineering Contradiction:

Improvealignment precisionVSAvoidconnector volume

Core Design Contradiction:

Manufacturing precisionVSVolume of moving object

Solution Approach 1:

By eliminating the ferrule component, the overall volume of the connector is reduced. The ferrule-less design removes the cylindrical ferrule housing and its associated mounting structures, resulting in a more compact connector that requires less physical space in the optical assembly.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The alignment features and connection mechanisms are integrated directly into the connector housing or nested within each other, eliminating the need for separate ferrule components. This nested integration reduces the overall connector volume while maintaining alignment precision.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 approach reduces manufacturing costs, simplifies the manufacturing process, minimizes physical space requirements, and enhances resistance to contamination, providing a more reliable and efficient fiber optic connection solution.

Implementation Method 1

elastic cantilevers

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

index matching gel

Methodology Applied

Scientific EffectRefraction: Refraction

Data Source

PatentUS11561357B2Fiber optic connection modules

Publication Date: 2023.01.24 COMMSCOPE CONNECTIVITY BELGIUM BVBA

AI summary

Telecommunications assemblies and modules incorporating demateable fiber optic connection interfaces for coupling non-ferrulized optical fibers.