Flexible Fiber Splitter Assembly for Single-End Optical Routing
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Solution Overview
Problem
Existing optical fiber connection apparatuses, such as splice trays and splitters, occupy significant space and require access to both ends for installation and servicing, complicating the management of large numbers of optical fibers in a compact space.
Innovation Solution
A flexible substrate optical fiber splitter assembly that routes and secures optical fibers on a flexible substrate, allowing all fibers to enter or exit from a single end, with controlled bend radii to minimize loss, and can be rolled into a compact cylindrical package for protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If traditional splice trays and splitters are used to manage optical fibers, then fiber connection functionality is provided, but the apparatus occupies significant space and requires access to both ends for installation and servicing
Solution Approach 1:
The patent transitions from traditional linear fiber routing (requiring access to both ends) to a compact folded configuration where all fibers enter and exit from a single end. This dimensional reorganization allows the splitter assembly to be mounted in a compact space within the fiber frame while maintaining full functionality and accessibility through a single access point.
Solution Approach 2:
The patent employs a folded fiber routing scheme where fibers are routed back through the same apparatus multiple times, nesting the fiber paths within each other. This allows the optical fibers to be managed in a compact footprint while still providing access to all connection points through a single end, effectively nesting the functionality within a reduced spatial envelope.
2Area of stationary object
If optical fibers are routed with tight bends to achieve compact packaging, then space requirements are reduced, but bending losses increase
Solution Approach 1:
The patent carefully controls the bend radius parameter of the optical fibers throughout the routing path, ensuring that all bends maintain a radius greater than the minimum specified in the claims. This parameter control allows the fiber assembly to be packaged in a compact cylindrical form factor while preventing excessive bending losses by maintaining bends within acceptable limits.
3Ease of manufacture
If individual optical fibers are handled extensively for splicing and splitting, then fiber interconnection is achieved, but the risk of fracturing and breakage increases
Solution Approach 1:
The patent performs the critical splicing and splitting operations in a controlled factory environment before final assembly, where precision equipment and controlled conditions minimize the risk of fiber damage. The pre-assembled units are then packaged and deployed as complete modules, eliminating the need for extensive field handling and reducing the risk of fiber fracturing during installation and servicing.
Data Source
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AI summary
A flexible optical fiber splitter assembly and method of manufacture. The method can include separating (1002), from an optical fiber bundle or ribbon comprising a plurality N of optical fibers, a first optical fiber to result in a first branch comprising the first optical fiber and a second branch comprising remaining N-1 optical fibers, splicing (1004), to the first optical fiber, an input fiber of a 1xM splitter comprising M optical fibers as outputs, attaching (1006) and/or routing, to a flexible substrate, a portion of one or more of the optical fiber bundle or ribbon, the first optical fiber, the remaining N-1 optical fibers, and the 1xM splitter to a flexible substrate such that each enter or exit from a first end of the flexible substrate and align with furcations of a housing. The method can include rolling (1008) the flexible substrate into a cylinder and installing (1010) the flexible substrate into a cylindrical housing.