Optical Fiber Connector Elastomeric Ferrule Alignment

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Solution Overview

Problem

Conventional optical fiber connectors for medical laser applications face challenges with alignment and heat management due to their small size and exposed fiber facets, leading to potential misalignment and excessive heat generation, which can damage the connectors and impact the integrity of the connection between the laser source and medical device.

Innovation Solution

The design features a launch connector with a compliantly positioned male ferrule within a tubular sleeve, supported by elastomeric material, allowing for radial and axial compliancy, and a heat transfer pathway that utilizes the receiving connector's structure to dissipate heat efficiently, eliminating the need for metal springs and simplifying assembly and manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the connector size is reduced to increase connector density, then the number of connectors per square inch increases, but the ease of handling and manipulation deteriorates

Engineering Contradiction:

Improveconnector densityVSAvoidease of handling

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The connector is divided into distinct functional segments: a compact optical connection portion for high-density mounting, and a separate mechanical connection portion with enlarged graspable features for ease of handling. The ferrule is further segmented from the housing, allowing independent optimization of each portion's dimensions and properties.

Inventive Principle:

Principle #1Segmentation

2Volume of moving object

If the ferrule is made small to reduce connector size, then the connector footprint decreases, but the risk of contamination and damage to the fiber facet increases

Engineering Contradiction:

Improveconnector footprintVSAvoidfiber facet integrity

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The small-diameter ferrule containing the fiber facet is nested within a larger-diameter housing that provides protective oversight. The housing acts as an outer shell that shields the vulnerable ferrule and fiber facet from contamination and damage during handling and connection operations.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Ease of manufacture

If the optical connection portions are fixed within the mechanical connection portions, then the manufacturing simplicity increases, but the alignment precision deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidalignment precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The ferrule is designed with dynamic positioning capability through resilient support elements that allow it to float and self-align within the housing. This dynamic arrangement enables the optical connection portion to automatically adjust its position to achieve precise alignment with the laser beam, while the fixed housing provides stable mechanical support.

Inventive Principle:

Principle #15Dynamics

4Device complexity

If conventional fixed optical connection portions are used, then the device complexity decreases, but the heat management capability deteriorates

Engineering Contradiction:

Improveconnector structure complexityVSAvoidheat dissipation

Core Design Contradiction:

Device complexityVSTemperature

Solution Approach 1:

Resilient support elements serve as intermediary components between the ferrule and housing, providing multiple functions: mechanical support, alignment assistance, and thermal conduction pathways. These intermediaries create extended heat transfer routes from the fiber facet through the ferrule and housing to surrounding structures, improving heat management without significantly increasing overall device complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution enhances alignment precision, reduces heat-related issues, and simplifies manufacturing by using elastomeric material for compliancy, while providing effective heat dissipation through the medical device connector, improving the reliability and robustness of the connection.

Implementation Method 1

The male ferrule is compliantly positioned within the tubular sleeve, supported by elastomeric material, allowing for radial and axial compliancy

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

a heat transfer pathway that utilizes the receiving connector's structure to dissipate heat efficiently

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11914199B2Optical fiber cable connector

Publication Date: 2024.02.27 IPG PHOTONICS CORP

AI summary

A laser light energy coupling with a male launch connecter. The male launch connector having a body portion with the fiber optic line terminating at an optical connection component including a male ferrule. The optical connection component being elongate and generally cylindrical with a central circumferential band. The body portion defining a cavity form fit and spaced about the optical connection component. An elastomeric support engaging the optical connection portion provides compliancy when the coupling is made and provides centration before the coupling is made. The elastomeric support positioned rearward of the optical connection component. The elastomeric support may clamp the fiber optic line therein. A forward facing annular surface displaced rearwardly of a forwardmost portion of the male ferrule provides a stop surface when the coupling is made and provides heat transfer means to dissipate heat from the male ferrule through into a receiving coupling.