Fiber Connector Gap Design for Angular Tolerance
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Solution Overview
Problem
Fiber-optic connectors face significant challenges with precise mechanical alignment requirements, leading to issues with lateral and angular misalignment, which result in signal loss and potential damage, especially in environments with vibration and dust, as existing solutions often require exotic and costly custom components.
Innovation Solution
A multi-ferrule connector design with a sleeve positioned forward of the housing creates a gap between the ferrule and the housing orifice, allowing for angular and lateral movement, and incorporates a wide shoulder and chamfered features to accommodate misalignment without compromising strength or requiring complex parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the connector housing orifice is made tight-fitting for the ferrule, then structural support and alignment precision are improved, but lateral and angular movement capability deteriorates
Solution Approach 1:
The connector is divided into two functional zones: a tight-fitting region (ferrule holder engaging the ferrule) that provides precise alignment and structural support, and a gap region (between ferrule and housing orifice) that allows lateral and angular movement. This segmentation enables both precision and adaptability to coexist in different parts of the same component.
Solution Approach 2:
Different regions of the connector have different fit characteristics: the ferrule holder region has tight tolerances for precision alignment, while the housing orifice region has intentional clearance (gap) for movement accommodation. This local differentiation of fit quality allows the connector to simultaneously achieve precision where needed and flexibility where beneficial.
2Adaptability or versatility
If custom narrow ferrule components are used to accommodate angular movement, then adaptability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The complexity of accommodating angular movement is extracted from the ferrule itself and transferred to the housing-ferrule interface geometry. Instead of modifying the ferrule into exotic narrow configurations, the housing orifice and ferrule holder are designed with specific gap dimensions and chamfered surfaces that naturally accommodate angular movement of standard ferrules.
Solution Approach 2:
Instead of making the ferrule narrow and complex to fit within a tight orifice, the invention inverts the approach: the ferrule maintains its standard form, and the housing orifice is designed with intentional clearance and chamfered surfaces that guide and accommodate the ferrule's movement. This reversal simplifies manufacturing while achieving the same functional result.
3Strength
If the ferrule is tightly constrained in the housing orifice, then structural integrity is improved, but tolerance for misalignment deteriorates
Solution Approach 1:
The connector transitions from a static tight-fit design to a dynamic clearance-fit design. The gap between the ferrule and housing orifice, combined with chamfered surfaces, allows the ferrule to dynamically adjust its position and angle during mating, accommodating misalignment while maintaining structural integrity through the ferrule holder engagement.
Data Source
Figure 1~2
Figure 3A~3B
Figure 3C~4
AI summary
A connector (400) having a front and rear orientation and configured to mate with a mating connector. Said connector (400) comprising a housing (401) and a ferrule (406) defining at least one borehole (407) for receiving a fiber, and having a ferrule diameter (d2) which is less than a diameter (d1) of an orifice (404) of the housing (401) through which it extends such that a gap (408) is defined between said ferrule (406) and said orifice (404) to allow said ferrule (406) to move within said orifice (404) angularly and laterally with respect to an axis (402a) of a cavity (402) of said housing (401). A sleeve (411) containing a lens (414) is disposed around a portion of said ferrule (406) forward of the orifice (404) of the housing (401) and extends beyond a front end of the ferrule (406).