Multi-fiber Connector with Pivoting Alignment Pins
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Solution Overview
Problem
Optical communication systems face high attenuation due to misalignment between multi-fiber optic connectors caused by manufacturing tolerances leading to a lack of perpendicularity between ferrule end faces and alignment pins, resulting in gaps that prevent effective physical contact and lead to substantial attenuation losses.
Innovation Solution
The design incorporates ferrules with alignment pins that can pivot relative to each other, allowing for angular misalignment compensation through modified contact areas and reduced resistance along specific axes, enabling effective physical contact even when perpendicularity is not present, utilizing a spring-loaded mechanism to facilitate this pivoting and ensure low-loss optical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional rigid alignment pins are used in multi-fiber connectors, then manufacturing precision can be maintained, but angular misalignment occurs due to lack of perpendicularity between ferrule end faces and alignment pins, causing gaps and high attenuation
Solution Approach 1:
The alignment pin is designed with a resilient portion that allows dynamic pivoting movement. The pin can rotate about its longitudinal axis within the ferrule, enabling the connector to adapt to angular misalignment between mated ferrules. This dynamic capability transforms the rigid alignment structure into a flexible one that compensates for manufacturing tolerances while maintaining reliable physical contact.
Solution Approach 2:
The alignment pin's contact characteristics are changed by modifying its transverse cross-sectional shape. The non-circular cross-section (e.g., square or rectangular) provides reduced contact area with the ferrule wall at specific locations, creating reduced resistance zones that facilitate easier pivoting. This parameter change in geometry enables the pin to pivot with lower torque while maintaining alignment functionality.
2Stability of the object's composition
If alignment pins with full contact surfaces are used, then structural stability is maintained, but pivoting resistance increases preventing compensation for angular misalignment
Solution Approach 1:
The alignment pin's cross-sectional geometry is designed with non-uniform contact characteristics. Specific portions of the pin's circumference have reduced contact area with the ferrule wall, creating localized low-friction zones. This local quality modification allows the pin to pivot easily in the desired direction while maintaining overall structural stability and alignment accuracy.
3Measurement precision
If ferrules are designed with high rigidity to maintain alignment, then positioning accuracy is improved, but ability to accommodate angular misalignment through deformation is reduced
Solution Approach 1:
The ferrule structure is segmented into distinct functional zones: a rigid portion that maintains alignment accuracy and a resilient portion that enables pivoting. The alignment pin itself is segmented with a rigid tip for precise fiber alignment and a flexible shaft that allows pivoting motion. This segmentation allows the ferrule to simultaneously achieve high positioning accuracy and adaptability to angular misalignment.
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
This solution ensures effective end-to-end face contact between ferrules, reducing attenuation and enhancing optical communication by accommodating manufacturing-induced misalignments, thereby maintaining low-loss optical connections despite angular misalignment.
Implementation Method 1
The ferrule is spring biased toward the front end of the connector body
Implementation Method 2
the portions of the ferrule supporting the alignment pins deform to accommodate pivotal movement of the alignment pins relative to the ferrule
Data Source
AI summary
A multi-fiber connector (40) that promotes physical contact with a communicating multi-fiber connector. The multi-fiber connector (40) has a connector body (44) with a front end (47) and a back end (49). The multi-fiber connector (40) also includes a ferrule (10a, 10b) with optical contacts (20a, 20b) at a front end (14a, 14b). The ferrule (10a, 10b) is spring biased toward the front end (14a, 14b) of the connector body (44). The ferrule (10a, 10b) has a pair of alignment pin openings (30a, 30b) extending into the ferrule from a front end (14a, 14b). The ferrule (10b) also has a pair of alignment pins (22) mounted within the alignment pin openings (30a, 30b). The base ends of the alignment pins (22) have a different transverse cross-sectional shape than the alignment pin openings (30a, 30b). This difference in transverse cross-sectional shapes allows the alignment pins to pivot relative to the ferrule along a major axis of the ferrule.