Floating Ferrule Optical Connector Alignment Mechanism
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Solution Overview
Problem
Existing optical connectors with complex structures and increased component counts struggle to maintain optical connection stability under external forces, particularly in high-speed and high-volume communication networks, due to the lack of ferrule movement in the optical axis direction and rotation.
Innovation Solution
An optical connector design featuring a ferrule with a flange and a coil spring biasing mechanism, allowing the ferrule to float and rotate within the plug frame, utilizing tapered and guide surfaces for alignment and stabilization, and a split sleeve for connection, which reduces component complexity and maintains optical alignment while absorbing external forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the ferrule is allowed to float and rotate within the plug frame, then the optical connection stability is improved by preventing external force transmission, but the device complexity increases due to additional movement mechanisms
Solution Approach 1:
The ferrule is designed to be movable relative to the plug frame in multiple directions (horizontal, vertical, and optical axis directions) and rotatable, transforming the static connection into a dynamic one that can absorb external forces while maintaining optical alignment
Solution Approach 2:
A floating structure with guide surfaces and elastic members is introduced as an intermediary mechanism between the ferrule and plug frame, enabling controlled movement and rotation to isolate the optical fiber from external forces
2Device complexity
If the ferrule is constrained to move only in directions perpendicular to the central axis, then the device complexity is reduced, but the optical connection reliability deteriorates due to inability to absorb external forces
Solution Approach 1:
The ferrule is designed to be movable relative to the plug frame in multiple directions (horizontal, vertical, and optical axis directions) and rotatable, transforming the static connection into a dynamic one that can absorb external forces while maintaining optical alignment
3Reliability
If an Oldham coupling mechanism is used to allow ferrule movement, then the optical connection stability is improved, but the manufacturing cost increases due to increased component count
Solution Approach 1:
The floating mechanism is divided into separate functional components: guide surfaces for alignment, elastic members for biasing, and a flange structure for movement control, allowing each component to be manufactured independently and assembled together
Solution Approach 2:
The complex Oldham coupling mechanism is simplified by extracting only the essential floating functionality and implementing it through simpler guide surfaces and elastic members, removing unnecessary intermediate components
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
The design ensures stable optical connections by allowing ferrule movement and rotation, reducing component count and manufacturing costs, while maintaining alignment and preventing external force transmission, thus supporting high-speed and high-volume communication networks effectively.
Implementation Method 1
an elastic member biasing the ferrule
Data Source
Figure 1
Figure 2~3
Figure 4A~4C
AI summary
An optical connector that requires fewer components and also has a simpler structure includes an optical fiber including a glass fiber and a resin coating surrounding the glass fiber; a ferrule having a flange outside the ferrule and a through-hole inside the ferrule, the ferrule holding, in the through-hole, a portion of the glass fiber exposed from the resin coating at an end of the optical fiber; a plug frame accommodating the ferrule; and an elastic member abutting the flange and biasing the ferrule. The flange has a flat surface on an outer periphery thereof, and the plug frame has a guide surface configured to unrotatably align the ferrule biased by the elastic member in contact with the flat surface of the flange. When the ferrule is moved in the direction opposite to the biasing direction, the flat surface is separated from the guide surface to bring the ferrule into a floating state relative to the plug frame.