Multi-Fiber Ferrule With Open Grooves For High Density Alignment
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Solution Overview
Problem
Current optical fiber connectors face challenges with tolerance issues due to deformation under load, thermal expansion, and epoxy creep, leading to high insertion and return losses, and are costly to manufacture, especially when accommodating high fiber densities.
Innovation Solution
The ferrule design features open grooves and alignment pin grooves instead of through-holes, allowing for precise fiber alignment with an interference fit, reducing environmental sensitivity and eliminating the need for epoxy, and can be fabricated using low-cost high-throughput processes like stamping and extrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional through-hole ferrule design with epoxy is used, then fiber alignment can be achieved, but the ferrule deforms under load and experiences thermal expansion leading to tolerance issues and high insertion/return losses
Solution Approach 1:
The ferrule is divided into two separate halves that are joined together, with each half containing precise grooves for fiber positioning. This segmentation allows the grooves to be precision-formed independently while the joining mechanism provides structural stability and resistance to deformation under load and thermal conditions.
Solution Approach 2:
The patent replaces the chemical bonding mechanism (epoxy) with a mechanical joining system consisting of interlocking features between the two ferrule halves. This mechanical system provides stable tolerance maintenance under load and thermal conditions without the creep and degradation issues associated with epoxy.
2Ease of manufacture
If molded plastic ferrule with oversized holes is used, then manufacturing is simplified, but alignment precision deteriorates due to clearance and deformation
Solution Approach 1:
The grooves for fiber positioning are precision-formed into the ferrule halves before the joining operation. This preliminary precision formation ensures that alignment tolerances are established early in the manufacturing process, and the subsequent joining of the two halves preserves these precise dimensions without requiring oversized holes or epoxy filling.
3Quantity of substance
If high fiber density is accommodated in traditional ferrule, then more fibers can be connected, but manufacturing cost increases and precision deteriorates
Solution Approach 1:
The patent transitions from a single-block ferrule design to a two-half ferrule construction, enabling fibers to be arranged in multiple layers or stacked configurations. This dimensional reorganization allows high fiber density to be achieved within a compact footprint while maintaining precision through the precision-formed grooves in each half and utilizing high-throughput stamping processes for manufacturing.
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 design achieves low insertion and return losses, enhances reliability, and allows for higher fiber density without significant footprint increase, while being less sensitive to thermal variations and easier to manufacture at a lower cost.
Implementation Method 1
allowing for precise fiber alignment with an interference fit
Data Source
AI summary
A ferrule for a high density optical fiber connector, supporting a first set of optical fibers of a first fiber cable and a second set of optical fibers of a second fiber cable. The ferrule supports the first and second sets of optical fibers in at least one plane. In one embodiment, the first set of optical fibers are supported in a first row of open grooves, and the second set of optical fibers are supported in a second row of open grooves. The optical fibers in the first row are staggered with respect to the optical fibers of the second row. The ferrule comprises two halves, each having an open structure that has a row of open grooves precisely formed thereon in a plane. In another embodiment, the ferrule supports the first and second sets of optical fibers in a single row, in an alternating interleaving manner.