Fiber Optic Connector Assembly With Elastic Alignment

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Solution Overview

Problem

Existing fiber optic connector systems face challenges in aligning components for all six degrees of freedom without misalignment due to different coefficients of thermal expansion (CTE), and they lack a separable interface for testing and manufacturing flexibility in photonic-enabled silicon transceivers.

Innovation Solution

A fiber optic connector assembly with a ferrule and connector design that includes alignment projections, latches, and an elastic element, allowing for separable and precise alignment of the ferrule relative to the transceiver, controlling all six degrees of freedom through a combination of mechanical and elastic components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If components are permanently attached to maximize coupling efficiency, then optical coupling efficiency is improved, but manufacturing flexibility and testing capability are lost

Engineering Contradiction:

Improveoptical coupling efficiencyVSAvoidmanufacturing flexibility and testing capability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The connector assembly is divided into separable components: a connector body, a ferrule with optical fibers, and an elastic element. This segmentation allows the components to be permanently attached for optimal coupling while still enabling separation for testing and manufacturing flexibility, resolving the contradiction between permanent attachment and adaptability.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If guide holes or guide pins are used to align the ferrule, then alignment precision is improved, but the system cannot accommodate different CTEs without misalignment during operation

Engineering Contradiction:

Improvealignment precisionVSAvoidalignment stability under thermal expansion

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The elastic element introduces dynamic compliance to the alignment system. Instead of rigid guide holes or pins that cannot accommodate thermal expansion differences, the elastic element allows for dynamic adjustment and compensation, maintaining alignment stability despite different CTEs of the components during temperature variations.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the mechanical parameters of the connection by using an elastic element with specific compliance characteristics. This allows the connection to adapt to thermal expansion differences through controlled deformation, maintaining alignment precision while accommodating different material CTEs.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If the ferrule is rigidly fixed to control all six degrees of freedom, then alignment precision is improved, but the ferrule cannot float relative to the connector

Engineering Contradiction:

Improvealignment precisionVSAvoidferrule floatability

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The elastic element transforms the rigid fixed connection into a dynamic, compliant connection. The ferrule is held with sufficient precision for alignment while allowing controlled movement and floating relative to the connector body, satisfying both alignment precision and floatability requirements.

Inventive Principle:

Principle #15Dynamics

4Adaptability or versatility

If a separable interface is implemented for testing and manufacturing flexibility, then adaptability is improved, but alignment precision and coupling efficiency may deteriorate

Engineering Contradiction:

Improvetesting and manufacturing flexibilityVSAvoidalignment precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The elastic element acts as an intermediary between the separable connector components. It enables the separable interface for testing and manufacturing flexibility while maintaining alignment precision through its compliance and load-bearing properties, preventing direct rigid contact that would compromise either separation capability or alignment precision.

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

Enables precise alignment and separable connection of fiber optic ferrules to optical transceivers, maintaining optical coupling efficiency while accommodating different CTEs and allowing for repeated assembly and disassembly without damage.

Implementation Method 1

an elastic element disposed between a top surface of the fiber optic ferrule and the connector, the elastic element biasing the fiber optic ferrule in a downward direction

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11573386B2Fiber optic connector assembly, apparatus for forming a transceiver interface, and ferrule

Publication Date: 2023.02.07 US CONEC LTD

AI summary

An fiber-optic connector assembly includes a fiber optic ferrule and a connector, which engage an optical transceiver component. The fiber optic ferrule engages a mating plane of a lens array in the optical transceiver component and floats within the connector. The engagement of the assembly and the optical transceiver component may be removable rather than fixed. The fiber optic ferrule also engages a mechanical interface to account for three degrees of freedom, while the engagement of the mating surfaces account for another three degrees of freedom.