Modular Ferrule Holder Assembly for High-Density Optical Connectors
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Solution Overview
Problem
High-density optical connector interfaces in data centers face challenges with increased complexity and obstruction issues, leading to potential network disruptions due to the compact arrangement of connectors and fibers, which complicates the assembly process and may result in latent defects and reduced quality of service.
Innovation Solution
A grouped ferrule holder assembly is introduced, comprising interconnected holder bodies that align and secure multiple transceiver ferrules within the optical connector interface, allowing for efficient positioning and connection of optical fibers, reducing physical obstructions and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the connector size and spacing are shrunk to increase panel connector density, then the quantity of connectors per panel increases, but the support cost increases and quality of service diminishes
Solution Approach 1:
The ferrule holder is divided into multiple modular holder bodies (e.g., first holder body, second holder body) that can be independently assembled and configured. Each holder body can accommodate a specific number of ferrules (e.g., 2, 4, or 8), allowing the system to be segmented into manageable units that maintain serviceability while achieving high density through modular scaling.
Solution Approach 2:
The patent transitions from traditional horizontal connector arrangements to a vertical three-dimensional configuration where ferrules are stacked in multiple layers (first plane, second plane, third plane) within a single holder body. This vertical stacking enables 8 ferrules to be accommodated in a compact footprint without increasing horizontal spacing requirements, thereby maintaining serviceability while achieving high connector density.
2Quantity of substance
If adjacent connectors are placed closer together to increase density, then more connectors fit in the same footprint, but access to individual release mechanisms becomes obstructed
Solution Approach 1:
The holder body serves as an intermediary structure that provides dedicated access channels and openings (e.g., first opening, second opening, third opening) allowing operators to reach release mechanisms (e.g., first release mechanism, second release mechanism) without physically pushing aside adjacent connectors or cables. This intermediary structure maintains operational accessibility while enabling dense connector packaging.
3Reliability
If tools are used to access release mechanisms in dense connector groups, then operator safety may improve, but the line of sight is obstructed and the process becomes time-consuming
Solution Approach 1:
The holder body design incorporates self-service features where the structural openings and access channels are built-in to the holder itself, allowing operators to directly access release mechanisms without requiring external tools. The holder body's own structure provides the necessary access paths, eliminating the need for screwdrivers or other tools while maintaining operator safety and reducing deployment time.
4Quantity of substance
If more ferrules are accommodated in the same footprint, then backward compatibility is maintained, but the assembly process becomes more complex
Solution Approach 1:
The ferrule holder is segmented into multiple independent holder bodies that can be assembled in a modular fashion. Each holder body is a discrete unit that can be manufactured and tested independently, then assembled together to form the complete 8-ferrule holder. This segmentation reduces assembly complexity compared to manufacturing a single monolithic 8-ferrule holder, while maintaining the capacity to accommodate 8 ferrules in a compact footprint.
Solution Approach 2:
Multiple holder bodies are merged or combined through holder-to-holder interfaces to form a unified ferrule holder assembly. This merging allows the system to achieve high ferrule capacity (8 ferrules) by combining simpler sub-units, thereby reducing overall assembly complexity while maintaining backward compatibility with existing connector footprints.
Data Source
AI summary
A ferrule holder assembly can support groupings of a transceiver ferrules in an optical connector interface of an optical transceiver. A first holder body holds a first grouping of transceiver ferrules and has a holder-to-holder interface. A second, typically identical, holder body holds a second grouping of transceiver ferrules. The holder-to-holder interface of the first holder body engages the holder-to-holder interface of the second holder body to operatively align the first holder body with the second holder body to position the first grouping of transceiver ferrules and the second grouping of transceiver ferrules in the optical connector interface for making optical connections to one or more optical connectors plugged into the optical connector interface. The ferrule holder assembly can be used in combination with pre-terminated fiber arrays to couple an optical interface to a circuit board in a transceiver.