Optical Cable Assembly for Mismatched Fiber Pitch Alignment
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Solution Overview
Problem
Existing optical fiber connectors struggle to efficiently connect optical fibers with disparate diameters, such as standard fibers and PIC connector pigtail fibers, due to mismatched diameters, which complicates the connection process.
Innovation Solution
An optical cable subassembly is designed with a cable retainer and light coupling unit that accommodate fibers of different diameters, allowing them to extend through retainer and coupling unit features at specific pitches, enabling rotation and bending to achieve proper alignment and mating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If optical fibers with different diameters are connected using existing connectors, then connection compatibility is improved, but alignment precision and connection reliability deteriorate due to mismatched diameters
Solution Approach 1:
A transition component is introduced between optical fibers of different diameters. This intermediary element has a first end that interfaces with the smaller diameter fiber and a second end that interfaces with the larger diameter fiber, enabling diameter transition while maintaining precise alignment. The transition component acts as a mediator that resolves the diameter mismatch problem without compromising alignment precision.
Solution Approach 2:
The connector design incorporates different structural characteristics at different locations to accommodate fibers of different diameters. The first portion of the connector is designed with features suitable for smaller diameter fibers, while the second portion is designed for larger diameter fibers. This local differentiation allows the single connector to handle multiple fiber types while maintaining optimal alignment at each interface.
2Device complexity
If a universal connector design is used for different fiber diameters, then device complexity is reduced, but connection reliability deteriorates
Solution Approach 1:
The connector is divided into distinct segments or portions, each optimized for specific fiber diameter ranges. Rather than using a single uniform design, the connector incorporates modular elements that can be selectively engaged depending on the fiber type. This segmentation allows each portion to provide reliable connection for its designated fiber size while keeping the overall device relatively simple through modular architecture.
3Manufacturing precision
If fibers are rigidly fixed in alignment features, then alignment precision is improved, but adaptability to different fiber lengths deteriorates
Solution Approach 1:
The alignment features incorporate dynamic or flexible elements that can adapt to different fiber lengths while maintaining precise alignment. Rather than rigid fixed positions, the design allows for controlled movement or adjustment within the alignment features, enabling them to accommodate varying fiber lengths. This dynamic capability ensures that fibers of different lengths can be properly aligned and connected without compromising connection precision.
Data Source
AI summary
An optical cable subassembly includes a plurality of optical fibers; at least one light coupling unit with a coupling unit attachment area configured to receive and hold a free end of each optical fiber of the plurality of optical fibers at a coupling unit pitch; and a cable retainer adapted to be installed in a housing and having a retainer attachment area with a plurality of spaced-apart retainer fiber alignment features arranged at a retainer pitch, each of the plurality of optical fibers disposed in and attached to one of the plurality of retainer fiber alignment features.