Modular Active Optical Cable Hybrid Assembly
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Solution Overview
Problem
Existing optical interconnect solutions fail to provide a viable solution for aerospace, military, and industrial applications due to limited ability to distribute electrical power, perform health monitoring, and accommodate customized cabling requirements, with a lack of modular design and manufacturing methods that scale to small volumes.
Innovation Solution
A method for creating modular multi-function active optical cables involving ruggedized electrical connectors, modular boards, hybrid cable assemblies with optical and electrical components, and an enclosure that allows for various connector types, pin arrangements, and power management, enabling flexible and customizable interconnect solutions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If optical interconnect solutions are implemented, then electromagnetic interference susceptibility is reduced and bandwidth is increased, but the ability to distribute electrical power and perform health monitoring is lost
Solution Approach 1:
The patent combines optical and electrical transmission capabilities within a single hybrid cable assembly. The cable includes both optical fibers for high-bandwidth data transmission and electrical conductors for power distribution and health monitoring, merging the advantages of both transmission types into one integrated solution.
Solution Approach 2:
The hybrid cable assembly is designed to perform multiple functions simultaneously: optical data transmission, electrical power distribution, and health monitoring. This multi-functional design allows a single cable to replace what would traditionally require separate optical and electrical cables, particularly benefiting aerospace and military applications.
2Adaptability or versatility
If customized cabling with different connectors and pin-outs is provided for each application, then adaptability to specific requirements is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The cable assembly is segmented into modular components: a standardized hybrid cable core with interchangeable connector assemblies. This allows the same cable construction to be adapted to different connector types (MIL-DTL-38999, D-sub, etc.) by simply changing the connector portion, reducing manufacturing complexity while maintaining customization capability.
Solution Approach 2:
The patent creates a universal cable construction that can accommodate multiple connector types and pin arrangements through a standardized interface design. This universal approach allows a single cable design to serve multiple applications with different connector requirements, reducing the need for completely custom cable designs for each application.
3Ease of manufacture
If standardized optical cable products are produced in high volume, then manufacturing cost is reduced, but the ability to accommodate customized requirements is limited
Solution Approach 1:
The cable assembly is divided into a standardized hybrid cable portion that can be mass-produced, and interchangeable connector assemblies that can be customized. This segmentation allows the core cable to be manufactured efficiently in volume while the connector portion can be adapted to specific customer requirements without impacting the manufacturing efficiency of the main cable construction.
4Adaptability or versatility
If electrical cables are used for interconnects, then power distribution and health monitoring capabilities are maintained, but cable size and weight increase
Solution Approach 1:
The patent merges optical and electrical conductors into a single hybrid cable assembly, consolidating multiple functions into one cable. This reduces the overall cable size and weight compared to using separate electrical cables for power and data, while maintaining all necessary capabilities including power distribution and health monitoring through the electrical conductors.
Data Source
AI summary
A method of making modular multi-function active optical cables (AOC) that enables multiple functions with minimal non-recurring engineering is described herein. In a non-limiting embodiment, one or more modular boards may be assembled into an assembly at a first end and a second end of the modular multi-function active optical cable, where each modular board may include at least a first connector. An electrical connector may be connected to the assembly using an interface to connect the electrical connector to the first connector associated with each module board. A hybrid cable assembly then may be connected between the assembly at the first end and the second, where the hybrid cable assembly includes one or more optical fibers and one or more electrical conductors.