Modular Optical Wet-Mate Connector Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current wet-mate connectors for optical fibers in harsh environments, such as underwater applications, are limited by their small optical-fiber count and lack of modularity, which restricts their scalability and reliability, especially when exposed to mechanical stress, vibration, and contamination.
Innovation Solution
A modular and scalable high optical-fiber count wet-mate connector assembly is designed, featuring a plug and receptacle connector system with alignment pins and slots, latching mechanisms, and floating socket contacts with spring backing, allowing for high fiber counts in a compact and robust package, capable of withstanding harsh conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional wet-mate connectors are used with limited optical-fiber count, then the connector structure remains simple and compact, but the scalability and reliability are restricted
Solution Approach 1:
The connector is divided into multiple independent connector units, each housing a specific number of optical fibers (e.g., 4-8 fibers per unit). These units can be modularly assembled to achieve high fiber counts while maintaining manageable complexity in each individual unit.
Solution Approach 2:
Multiple connector units are combined within a single connector assembly, allowing the system to achieve high optical-fiber count by aggregating the capacity of individual units while sharing common structural elements like the wet-mate interface and sealing mechanism.
2Reliability
If traditional wet-mate connectors are used, then the sealing mechanism is simple, but the reliability under mechanical stress and vibration is insufficient
Solution Approach 1:
The sealing mechanism incorporates pre-loaded spring elements and compliant structures that provide cushioning and compensation for mechanical stress and vibration before failure can occur. The spring backing and floating socket contacts absorb shock and vibration energy.
Solution Approach 2:
The sealing mechanism uses material and structural parameter changes to adapt to harsh environments, including elastic deformation of sealing elements under pressure, thermal expansion compensation, and pressure-balanced chamber design that maintains sealing effectiveness across varying operating conditions.
3Quantity of substance
If traditional wet-mate connectors are used, then the connector size is compact, but the scalability for high fiber counts is limited
Solution Approach 1:
The connector assembly is segmented into multiple units that can be configured in series or parallel arrangements, allowing high fiber counts to be achieved by combining standard-sized units rather than designing a single large connector.
Solution Approach 2:
Multiple connector units are nested or stacked within the overall connector assembly, with smaller units fitting within or alongside larger units, thereby achieving high fiber counts without proportionally increasing the external dimensions.
4Manufacturing precision
If traditional wet-mate connectors are used, then the alignment and latching features are simple, but the precision and robustness of connection are insufficient
Solution Approach 1:
The alignment and latching function is divided into multiple independent features distributed across different connector units, with each unit contributing to the overall alignment precision through its own alignment pins, slots, and latching mechanisms.
Solution Approach 2:
Alignment pins and slots serve as intermediary elements that mediate between the plug and receptacle units, ensuring precise alignment of the optical fibers before final latching occurs. These intermediary features compensate for manufacturing tolerances and positioning errors.
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 solution enables reliable high-fiber count connections in harsh environments with improved mechanical robustness and scalability, reducing the risk of fiber loss due to individual connector failure and maintaining reliability across multiple mating cycles.
Implementation Method 1
floating socket contacts with spring backing
Data Source
AI summary
A modular and scalable high optical fiber count connector assembly (800) is formed by engagement mating of a plug connector (500) to a receptacle connector (700). The plug connector (500) includes a plug shell unit (200) and a pin subassembly unit (400), which includes a plurality of small form factor engagement mate pin connectors (100). The plug connector (500) is formed by inserting the pin subassembly unit (400) into the plug shell unit's (200) hollow body (230). The receptacle connector (700) includes a receptacle shell unit (300) and a socket subassembly unit (600), which includes a plurality of small form factor engagement mate socket connectors (150). The receptacle connector (700) is formed by inserting the socket subassembly unit (600) into the receptacle shell unit (300) hollow body (330).