Ferrule-less Multi-Fiber Connectors Using Gel-Groove Assembly
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Solution Overview
Problem
Conventional multi-fiber connectors are prone to debris accumulation, making them difficult to clean and manufacture, and the use of ferrules is costly and time-consuming, with the added challenge of polishing optical fiber tips without damage.
Innovation Solution
A connectorized optical cable system that eliminates the need for ferrules by using a gel-groove assembly and spring assembly to clean and position optical fibers, with sub-modules over-molded around arrays of fibers and angled tips formed to facilitate easy insertion and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional multi-fiber connectors with ferrules are used, then optical fibers can be held and positioned, but debris accumulates on fibers and in ferrules making them difficult to clean
Solution Approach 1:
The patent removes ferrules entirely from the connector design, extracting the source of debris accumulation. Without ferrules to collect and harbor debris, the connector becomes much easier to clean and maintain, directly resolving the contradiction between ease of cleaning and debris accumulation
Solution Approach 2:
The connector design allows fibers to be held and positioned without ferrules, enabling a self-service approach where the fiber array itself maintains alignment without additional components that would require cleaning. The gel-groove assembly provides automatic alignment and retention without ferrule-related debris issues
2Ease of manufacture
If ferrules are used to hold optical fibers, then fibers are positioned and protected, but manufacturing becomes expensive and time-consuming
Solution Approach 1:
The patent eliminates ferrules from the manufacturing process entirely, removing a complex and expensive component. This extraction simplifies manufacturing steps, reduces material costs, and eliminates the time-consuming processes of ferrule assembly and fiber insertion into ferrules
Solution Approach 2:
The patent combines the functions of ferrule holding, positioning, and protection directly into the connector housing and gel-groove assembly. This merging eliminates the need for separate ferrule components and their associated manufacturing steps, reducing overall device complexity while maintaining functional requirements
3Manufacturing precision
If optical fibers are inserted into ferrules, then fibers are held securely, but polishing becomes difficult and risky due to fiber density
Solution Approach 1:
The patent removes ferrules before the polishing step occurs, eliminating the constraint that made polishing difficult. Without ferrules in place, fiber tips can be polished more easily and safely, improving both manufacturing ease and potential polishing quality
Solution Approach 2:
The patent performs fiber tip preparation and polishing before final insertion into the connector housing, rather than after ferrule installation. This preliminary action allows for better access and control during polishing, reducing the risk of fiber damage while maintaining secure holding in the final assembly
4Quantity of substance
If multiple optical fibers are densely packed in connectors, then fiber capacity increases, but cleaning becomes more difficult
Solution Approach 1:
The patent removes ferrules that created debris traps in densely packed fiber connectors. Without ferrules, there are fewer surfaces and crevices for debris to accumulate, making cleaning easier even with high fiber density
Solution Approach 2:
The patent uses a gel-groove assembly that provides a flexible, smooth surface for fiber insertion and retention. This flexible structure reduces sharp edges and complex geometries where debris could accumulate, facilitating easier cleaning while maintaining dense fiber packing
Data Source
AI summary
A connection system includes an optical connector assembly; and an optical plug. The connector assembly includes a stack of gel-groove assemblies and a spring assembly mounted within a housing. Each of the gel-groove assemblies includes a first gel block at a first axial end, a second gel block at a second axial end, and a fiber mating region between the first and second gel blocks. The optical plug including sub-modules over-molded over arrays (e.g., ribbons) of the optical fibers. Each sub-module defines notches for receiving latches of the spring assembly when the optical plug is coupled to the first axial end of the optical adapter. Bare optical fibers extend from the plug, pass through the first axial gel block, and enter the fiber mating region when the plug is coupled to the adapter.