Fiber Optic Connector Split Sleeve Alignment
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Solution Overview
Problem
Fiber optic connectors fail to maintain stable alignment between internal and external optical fibers under side load and agitation, leading to misalignment and significant optical power changes.
Innovation Solution
The design incorporates a cylindrical split sleeve with varying clearance within a shell, allowing the split sleeve to shift and maintain alignment, coupled with keyed features to prevent rotation and ensure stable fiber alignment during side loads and agitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fiber optic connector uses a fixed alignment structure, then the manufacturing precision is improved, but the reliability under side load and agitation deteriorates
Solution Approach 1:
The split sleeve is designed to be movable within the shell, allowing it to dynamically adjust its position in response to side loads and agitation. The clearance between the split sleeve and shell enables the sleeve to shift and rotate, maintaining fiber alignment despite external forces, thus resolving the contradiction between fixed manufacturing precision and dynamic reliability.
Solution Approach 2:
The patent changes the physical parameters of the alignment structure by introducing variable clearance zones within the shell. The different clearance amounts at different positions allow the split sleeve to have controlled mobility, transforming the rigid fixed-precision structure into a flexible system that maintains alignment through parameter adjustment under load.
2Manufacturing precision
If the split sleeve is tightly fitted in the shell, then the manufacturing precision is improved, but the reliability under side load deteriorates
Solution Approach 1:
The shell is designed with non-uniform clearance distribution, having different clearance amounts at different locations. This local quality variation allows the split sleeve to have controlled mobility in specific directions while maintaining precision in critical alignment zones, resolving the contradiction between tight fitting and side load reliability.
3Reliability
If keyed features are added to prevent rotation, then the reliability under agitation is improved, but the device complexity increases
Solution Approach 1:
Keyed features are introduced as asymmetric elements into the otherwise symmetric connector structure. These keyed features selectively prevent rotation while maintaining the overall simplicity of the design, providing reliability under agitation with minimal increase in device complexity.
Data Source
AI summary
Fiber optic connectors for use in connecting and aligning two optical fibers. In one example embodiment, a fiber optic connector includes a body, a cylindrical split sleeve at least partially positioned within the body, and a shell at least partially positioned within the body and surrounding the split sleeve. The body defines an internal port and an external port. The split sleeve defines a slot along the length of the split sleeve and has first and second open ends. The first end is configured to receive and grip a ferrule of an internal optical fiber and the second end is configured to receive and grip a ferrule of an external optical fiber. The portion of the shell surrounding the first end has a greater inside clearance than the portion of the shell surrounding the second end.