Multi-Fiber Connector Alignment Towers and Split Sleeves
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Solution Overview
Problem
The existing small form factor multi-fiber connectors, such as the Next Generation Data Center Connector (NGDC), are prone to misalignment and damage due to inadequate support for pins and brackets during connector insertion and cleaning, which can lead to ferrule alignment issues.
Innovation Solution
The design incorporates split sleeves and additional support features, such as cylindrical alignment towers and molded webs, within the adapter to securely hold and align male features on the NGDC ferrule, ensuring proper alignment and preventing damage, similar to LC and SC connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pins are held in the Male adapter using a metal bracket, then the connector can be assembled, but the pins and bracket are susceptible to bending during connector insertion and pin cleaning, causing misalignment and damage
Solution Approach 1:
The adapter is divided into separate functional components: a body portion and a pin support portion. The pin support portion is detachably coupled to the body portion, allowing the pins to be held securely in a dedicated support structure rather than a generic metal bracket. This segmentation enables optimized support for each component, improving pin alignment stability while maintaining ease of assembly.
Solution Approach 2:
A pin support portion acts as an intermediary component between the adapter body and the pins. This intermediate structure provides dedicated support and alignment features for the pins, preventing direct contact between the pins and the metal bracket that causes bending. The pin support portion mediates the interaction, ensuring stable alignment during insertion and cleaning operations.
2Device complexity
If the metal bracket provides minimal support, then the adapter structure remains simple, but the pins are prone to bending and misalignment during use and maintenance
Solution Approach 1:
The adapter structure is segmented into a body portion and a pin support portion that are detachably coupled. This segmentation allows the pin support portion to incorporate precision alignment features without complicating the overall adapter design. The modular approach enables manufacturing precision to be achieved in the pin support portion while keeping the adapter body structure relatively simple.
Solution Approach 2:
The pin support portion provides localized precision support where it is most needed - at the pin alignment locations. Rather than making the entire adapter structure complex, the invention applies enhanced support features locally at the critical pin interface areas. This local quality approach improves ferrule alignment accuracy without significantly increasing overall device complexity.
Data Source
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AI summary
A fiber optic connector has a housing and a ferrule contained within the housing. The ferrule has a base portion, an endface portion protruding from the base, and at least one alignment tower extending from the base portion parallel to the endface portion. In one embodiment, the ferrule can have one alignment tower on each side of the endface portion. In one embodiment. The alignment towers extend the same distance from the base portion as the endface portion. In another embodiment, the alignment towers may be connected to the endface portion via webbing.