Micro-ferrule Pre-terminated Micro-cable for High-Density Fiber Networks
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Solution Overview
Problem
The existing technologies for fiber optic networks, particularly in FTTx configurations, face challenges with high-density pre-terminated cable solutions that can be used with microducts, leading to labor-intensive fusion splicing and limited optical fiber density due to the size constraints of conventional connectors.
Innovation Solution
The use of micro-ferrules with a 2D array pattern of microholes, allowing for high-density optical connectors that can be installed in microducts with an inner diameter of up to 4 millimeters, enabling a higher fiber count without increasing the cable's cross-sectional diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional MPO-based connectors are used, then the connector structure is simple and well-established, but the cable cross-sectional diameter becomes too large to be accommodated in microducts with inner diameter of 8 millimeters
Solution Approach 1:
The connector is divided into multiple micro-ferrules, each handling a subset of optical fibers. This segmentation allows the overall connector assembly to be compact and fit within microduct constraints while maintaining the functionality of connecting multiple fibers simultaneously.
Solution Approach 2:
The patent transitions from conventional planar connector arrangements to a three-dimensional stacked configuration of micro-ferrules. This dimensional change enables higher fiber density and compact footprint, allowing the connector to fit within the limited space of microducts.
2Ease of manufacture
If fusion splicing is used to connect optical fibers in the field, then the connection can be made with existing equipment, but the labor and time required for splicing becomes significant and quality varies widely
Solution Approach 1:
The optical fibers are pre-terminated with micro-ferrules at the factory before deployment. This preliminary action eliminates the need for time-consuming field splicing operations, as the connectors are ready for immediate installation and connection in the field.
3Quantity of substance
If the cable is designed to accommodate high fiber count to increase bandwidth, then the optical fiber density increases, but the cable cross-sectional diameter increases making it incompatible with microducts
Solution Approach 1:
Multiple micro-ferrules are nested or tightly packed within the cable assembly in a compact arrangement. This nesting approach allows high fiber count to be accommodated within a small cross-sectional diameter, maintaining compatibility with microduct specifications.
Solution Approach 2:
The patent employs different packaging densities and arrangements for different regions of the cable assembly. Optical fibers are locally optimized for compact packing in specific zones, enabling high overall fiber density while maintaining a small external diameter suitable for microduct installation.
Data Source
AI summary
Micro-ferrules and pre-terminated micro-cable assemblies are disclosed. The micro-ferrules are configured for making and using cable assemblies in micro-ducts. The pre-terminated micro-cable assembly includes a main cable and one or more subunits that include a pre-selected number of optical fibers arranged within the main cable. Each of the one or more subunits includes at least a first end terminated with a micro-ferrule.