Octagonal Ferrule Geometry for Size 8 Cavity Integration
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Solution Overview
Problem
Standard 'Size 8' cavities in multi-contact connectors are not optimized for MT ferrules with high cross-sections, preventing the integration of multiple optical fibers due to size incompatibility and requiring significant manufacturing investments or reducing the number of optical channels.
Innovation Solution
The ferrule's geometry is modified to a convex polygon or octagonal cross-section, allowing it to fit within standard 'Size 8' cavities while maintaining a large number of optical channels, with guide arms for precise alignment and compactness, avoiding changes to pin diameters or polishing tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a standard MT ferrule with rectangular cross-section is used, then it can accommodate up to 72 optical fibers, but it cannot be inserted into a standard Size 8 cavity due to its large cross-sectional diameter
Solution Approach 1:
The ferrule cross-section is changed from a rectangular shape to a shape with curved sides (convex polygon or octagon). This geometric parameter change reduces the inscribed circle diameter while maintaining the same ferrule body dimensions and optical channel capacity, allowing insertion into standard cavities without reducing fiber capacity.
Solution Approach 2:
The rectangular cross-section with sharp corners is replaced by a cross-section with curved sides. The convex polygon or octagonal shape with rounded edges reduces the maximum diameter requirement for cavity insertion while preserving the internal volume and optical channel arrangement capacity for housing multiple fibers.
2Volume of moving object
If the cross-section of MT ferrule is reduced to fit standard cavities, then it can be inserted into Size 8 cavities, but the number of optical channels decreases and manufacturing investment increases
Solution Approach 1:
The invention changes the cross-sectional geometry from rectangular to convex polygon/octagonal with curved sides. This parameter change allows the ferrule to fit standard cavities while maintaining the same ferrule length and optical channel density, thus preserving the number of optical channels without reducing the effective fiber capacity.
Solution Approach 2:
Instead of reducing the ferrule dimensions in all directions, the invention modifies only the cross-sectional shape while maintaining the ferrule's longitudinal dimensions and internal channel arrangement. This selective dimensional modification allows cavity compatibility without compromising fiber capacity.
3Manufacturing precision
If guide arms are added to the ferrule for precise alignment, then positioning precision is improved, but the device complexity increases
Solution Approach 1:
Guide arms are added only to specific ferrules (male or female connectors) rather than both, creating an asymmetric configuration. This reduces the overall system complexity compared to adding guide arms to all ferrules, while still achieving precise alignment functionality through the complementary male-female guide arm interaction.
Solution Approach 2:
The alignment function is segmented into separate guide arms that can be independently positioned and configured on male and female connectors. This modular approach allows precise alignment without requiring complex integrated alignment mechanisms on both connectors, reducing overall device complexity.
Data Source
Figure 1A~1C
Figure 1D~2B
Figure 3~4B
AI summary
Optical connection assembly comprising: - a first optical contact (2) comprising at least one body (20) intended to enclose at least partially laterally a first ferrule (13) and constituting the housing for the first ferrule (13), at least one first guide arm (21) extending beyond the front face of the first ferrule (13) and at least one second guide arm (23) beyond which the body of the ferrule (13) extends,