2D Fiber Array Alignment Without Ferrules
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Solution Overview
Problem
There is a need for multi-fiber connectors that can connect a larger number of fibers at a higher spatial density than conventional connectors, and methods for fabricating and using these higher density multi-fiber connectors.
Innovation Solution
The development of fiber optic cable assemblies featuring two-dimensional arrays of stripped optical fibers, where the perimeter external surfaces of the 2D fiber arrays are used as datum surfaces for alignment structures, enabling the creation of high-density fiber optic connectors without conventional ferrules. This involves using alignment pins, precision glass tubes, fusion glass sheets, glass rods, fiber array rafts, V-blocks, and other structures to achieve precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional ferrule-based multi-fiber connectors are used, then fiber alignment can be achieved through pitch and eccentricity control, but the spatial density of fiber connections is limited
Solution Approach 1:
The patent transitions from conventional one-dimensional linear arrays of optical fibers to two-dimensional arrays, arranging fibers in a grid pattern. This dimensional change enables significantly higher spatial density of connections while maintaining alignment precision through the use of alignment features integrated into the 2D array structure itself, eliminating the need for traditional ferrules.
2Quantity of substance
If the number of optical fibers in connectors is increased to achieve higher density, then more connections can be made, but the connector size and complexity increase
Solution Approach 1:
The patent merges the alignment features directly into the 2D fiber array structure itself, eliminating the need for separate ferrule components. The alignment features are integrated as part of the array substrate, reducing the number of discrete parts and simplifying the overall connector assembly while accommodating higher fiber counts.
Solution Approach 2:
The patent extracts and eliminates the traditional ferrule component from the connector design. By using the 2D array substrate itself as the alignment reference structure, the design removes the ferrule layer, reducing component count and simplifying manufacturing while maintaining alignment capability.
3Manufacturing precision
If traditional ferrule-based alignment methods are used, then alignment can be achieved through alignment pins and ferrule structures, but the manufacturing process becomes more complex
Solution Approach 1:
The patent extracts and removes the separate ferrule component from the manufacturing process. By integrating alignment features directly into the 2D fiber array substrate, the design eliminates the need to manufacture and assemble separate ferrule parts, simplifying the manufacturing process while maintaining sub-micron alignment accuracy.
Data Source
AI summary
Perimeter external surfaces of a 2D arrays of stripped optical fibers are used as datum surfaces for alignment structures for mating connectors in fiber optic cable assemblies. 2D fiber arrays may include involutions and/or protrusions to serve as mating locations for alignment structures and/or to serve as keying structures. A removable sleeve may be positioned around at least a portion of a 2D fiber array to align mating connectors and/or bias alignment structures toward one another. Fiber-free areas may be provided in an interior of a 2D fiber array to receive alignment structures. One or more compliant members may be configured to press first and second alignment structures toward one another proximate to a 2D fiber array. A cable assembly fabrication method includes forming window stripping and adhering optic fiber groups while preventing adhesive material from protruding beyond outermost surfaces of optical fibers at a perimeter of a fiber array. Multiple 2D fiber arrays with peripheral protective structures may be received in a connector sleeve and biased toward one another.