Miniature Mechanical Transfer Optical Coupler for Fiber Splitting
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Solution Overview
Problem
Current methods for connecting one optical fiber ribbon to two others require active alignment and physical alteration of fibers, which is time-consuming and difficult to alter or disconnect without cutting the fibers.
Innovation Solution
A miniature mechanical transfer optical coupler (MMTOC) that uses a beam splitting element and collimating lenses to communicatively connect optical fibers without them touching or being physically altered, utilizing alignment elements to attach MT connectors and split light beams between multiple optical fiber ribbons.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If active alignment and physical alteration methods (fusing, bonding) are used to connect optical fiber ribbons, then reliable light transmission is achieved, but the process becomes time-consuming and difficult to alter or disconnect
Solution Approach 1:
The patent introduces an intermediary mechanical transfer connector system that mediates between optical fiber ribbons. Instead of directly fusing or bonding fibers together, the connector serves as an intermediate device that receives fibers from one ribbon and transfers them to another ribbon through mechanical coupling. This allows reliable light transmission while avoiding time-consuming active alignment and permanent physical alterations, enabling easy disconnection and reconfiguration.
Solution Approach 2:
The patent replaces the optical alignment and fusion system with a mechanical transfer connector system. Instead of using complex optical alignment procedures and thermal fusion processes, the invention uses purely mechanical means (connectors, ferrules, and coupling mechanisms) to establish and maintain light transmission paths between fiber ribbons. This substitution dramatically reduces connection time and enables easy modification without cutting or splicing fibers.
2Adaptability or versatility
If star coupler method is used to split signals from one optical fiber ribbon into two, then signal distribution is achieved, but manufacturing is time intensive and requires great precision
Solution Approach 1:
The mechanical transfer connector acts as an intermediary device that simplifies signal distribution from one optical fiber ribbon to two ribbons. Instead of requiring precise manual alignment and fusion of multiple fibers in a star configuration, the connector provides a pre-configured mechanical structure that automatically establishes the distribution paths. This eliminates the need for great manufacturing precision while maintaining full signal distribution capability.
3Adaptability or versatility
If optical wave guides on silicon are used to split optical signals, then signal routing is achieved, but the method becomes expensive and complex
Solution Approach 1:
The patent replaces complex silicon-based optical wave guide fabrication with a mechanical transfer connector system. Instead of depositing silicon dioxide layers, etching wave guide tunnels, and performing complex semiconductor manufacturing steps, the invention uses simple mechanical connectors that can be assembled without specialized fabrication facilities. This substitution dramatically reduces manufacturing complexity and cost while maintaining signal routing capability.
Solution Approach 2:
The patent segments the optical coupling function into separate, modular connector components. Instead of creating a monolithic silicon wave guide structure that requires complete fabrication before use, the mechanical transfer connector is divided into separable parts (ferrules, coupling mechanisms, mounting structures) that can be manufactured independently and assembled. This segmentation simplifies manufacturing and reduces overall device complexity.
4Stability of the object's composition
If fibers are actively coupled through fusing or bonding, then permanent connection is achieved, but the connection cannot be easily altered or disconnected without cutting the fiber
Solution Approach 1:
The mechanical transfer connector serves as an intermediary device that provides stable light transmission while enabling easy reconfiguration. Instead of permanently fusing or bonding fibers together, the connector creates a stable mechanical coupling that maintains optical alignment but allows the entire assembly to be disconnected and reconfigured. This resolves the contradiction by decoupling transmission stability from permanent physical bonding.
Solution Approach 2:
The patent introduces dynamic reconfigurability to the optical connection system through mechanical connectors. Instead of static, permanent fused connections, the mechanical transfer connector allows the system to be dynamically adjusted, disconnected, and reconfigured as needed. The connector maintains stable optical coupling during operation but enables flexible changes when required, achieving both stability and adaptability.
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 efficient and flexible communication between multiple optical fiber ribbons without the need for active alignment or physical alteration of fibers, reducing complexity and time while maintaining precise light transmission.
Implementation Method 1
The beam splitting element may comprise a first, second, third, and fourth side as well as a reflective portion for partially transmitting and partially reflecting light beams
Implementation Method 2
The first collimating lens may be fixed at the first side of the beam splitting element, the second collimating lens may be fixed at the second side of the beam splitting element
Data Source
AI summary
A miniature mechanical transfer (MT) optical coupler (“MMTOC”) for optically connecting a first plurality of optical fibers with at least one other plurality of optical fibers. The MMTOC may comprise a beam splitting element, a plurality of collimating lenses, and a plurality of alignment elements. The MMTOC may optically couple a first plurality of fibers disposed in a plurality of ferrules of a first MT connector with a second plurality of fibers disposed in a plurality of ferrules of a second MT connector and a third plurality of fibers disposed in a plurality of ferrules of a third MT connector. The beam splitting element may allow a portion of each beam of light from the first plurality of fibers to pass through to the second plurality of fibers and simultaneously reflect another portion of each beam of light from the first plurality of fibers to the third plurality of fibers.