2D Fiber Array Alignment Using Peripheral Datum Surfaces
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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 use of fiber optic cable assemblies with two-dimensional arrays of stripped optical fibers, where the perimeter external surfaces of the 2D fiber array serve as datum surfaces for alignment structures, such as alignment pins, precision glass tubes, and glass sheets, to enable high-density connector mating without conventional ferrules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional ferrule-based multi-fiber connectors are used, then fiber alignment and connection are achieved, but the spatial density and number of fibers per connector are limited
Solution Approach 1:
The patent transitions from traditional one-dimensional linear arrays of optical fibers to two-dimensional planar arrays, allowing significantly more fibers to be packed into a compact connector footprint. This dimensional change enables higher fiber density without proportionally increasing connector size, directly resolving the contradiction between quantity of fibers and connector area.
Solution Approach 2:
The patent integrates multiple functional elements directly into the fiber array structure itself, eliminating the need for separate ferrule components. The fiber array serves simultaneously as the mechanical support structure, alignment reference, and optical transmission medium, consolidating functions that traditionally required separate ferrule parts and enabling higher density.
2Quantity of substance
If higher density fiber arrays are implemented, then spatial efficiency improves, but manufacturing precision and alignment accuracy become more challenging
Solution Approach 1:
The patent designs the fiber array structure to self-align during assembly by using the peripheral fibers themselves as the reference datum for alignment. The outermost fibers in the two-dimensional array serve as built-in alignment references, eliminating the need for external ferrule-based alignment mechanisms and maintaining high precision even as density increases.
Solution Approach 2:
The patent changes the geometric parameters of the fiber array, specifically transitioning to a two-dimensional configuration with controlled pitch and spacing. By carefully designing the lateral spacing and using the peripheral fibers as alignment datums, the system maintains manufacturing feasibility and alignment accuracy while achieving higher fiber density.
3Area of stationary object
If ferrule components are eliminated for higher density, then connector size reduces, but alignment structures must be integrated directly into the fiber array
Solution Approach 1:
The patent merges the alignment reference function directly into the fiber array structure by designating peripheral fibers as alignment datums. This integration eliminates separate ferrule components and their associated alignment mechanisms, reducing connector footprint while the modular fiber array design keeps integration complexity manageable.
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.