High Density Fiber-Optic Connector Alignment Pin Design
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Solution Overview
Problem
The existing fiber-optic connector systems, particularly those using MT ferrules, face limitations in accommodating a large number of fiber optic cables due to physical design constraints, leading to reduced bandwidth and difficulties in removing or replacing installed ferrules, especially in aerospace and defense applications where high-density connections are required.
Innovation Solution
The design incorporates reduced-diameter press-fit alignment pins that serve both alignment and retention functions, allowing for a single fastener to secure the retainer and insert, thereby freeing up space for additional ferrules and simplifying the installation process by eliminating the need for oversized screws and improving accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional alignment pins with retaining screws are used, then secure alignment is achieved, but space is consumed limiting ferrule capacity
Solution Approach 1:
The patent combines the alignment pin and retention screw into a single integrated component. The alignment pin features an enlarged head portion that serves both as an alignment reference and as a retention mechanism, eliminating the need for separate retaining screws. This merging of functions frees up space within the connector housing, allowing for additional ferrules to be accommodated while maintaining precise alignment capability.
Solution Approach 2:
The alignment pin is designed to perform multiple functions: it provides alignment reference surfaces for precise positioning, acts as a retention mechanism through its enlarged head portion, and serves as a mounting feature for the ferrule. This multi-functional design eliminates the need for separate components, thereby increasing the number of ferrules that can be accommodated in the connector.
2Reliability
If multiple fasteners are used to secure retainer and insert, then secure connection is achieved, but space is consumed and installation complexity increases
Solution Approach 1:
The patent merges the functions of multiple fasteners into a single integrated alignment pin with an enlarged head. This single component simultaneously secures the retainer to the insert and provides alignment, eliminating the need for multiple separate fasteners. The result is a simpler assembly process with fewer parts while maintaining secure connection reliability.
3Manufacturing precision
If conventional alignment pins are used, then alignment is achieved, but oversized screws are required reducing accessibility
Solution Approach 1:
The patent extracts the retention function from oversized screws and integrates it into the alignment pin itself. By removing the need for separate large screws, the design improves accessibility while maintaining alignment precision. The alignment pin's enlarged head provides sufficient retention without requiring the bulky fasteners that hinder accessibility.
Data Source
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AI summary
A connector sub-assembly comprising: (a) an insert housing (206) defining two or more insert ferrule openings (118(a), 118(b)) and at least two insert alignment pin openings, and having a mating surface; (b) a retainer (210) attached to the insert and defining two or more retainer ferrule openings and at least two retainer alignment pin openings; (c) at least two alignment pins (204(a), 204(b)), each of the alignment pins disposed in one the insert alignment pin openings and in one of the retainer alignment pin openings, thereby aligning the insert ferrule openings and the retainer ferrule openings, the at least two alignment pins extending from the mating surface; and (d) only one fastener (208) securing the insert and the retainer.