Flexible Optical Circuit Cassette for Connector Transition Testing
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Solution Overview
Problem
The management of fiber optic cables in telecommunications networks is hindered by challenges in installation ease, accessibility, and maintenance, particularly in managing the transition between different types of connectors.
Innovation Solution
The use of fiber optic cassettes with flexible optical circuits that include a body, connectors, and a flexible substrate supporting optical fibers, allowing for the transition between multi-fiber and single or dual fiber connectors, reducing the need for manual handling and enabling controlled bending and tolerance accommodation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional fiber optic cable management methods are used, then installation and maintenance are complex and labor-intensive, but the flexible optical circuit with rigid support enables automated assembly and reduced manual handling
Solution Approach 1:
The fiber optic cable is segmented into multiple individual optical fibers that are separately supported and terminated on the flexible substrate, allowing each fiber to be independently managed and assembled, which simplifies the overall installation process
Solution Approach 2:
The flexible optical circuit acts as an intermediary component between the rigid connector array and the flexible cable assembly, providing a transition zone that enables automated positioning and reduces manual handling requirements
2Manufacturing precision
If rigid connector arrays are used for fiber termination, then connection precision is improved, but flexibility and adaptability to connector variations are reduced
Solution Approach 1:
The flexible substrate provides dynamic adaptability by allowing the optical fiber positions to be adjusted and accommodated to different connector configurations, while the rigid ferrules maintain precise alignment during the dynamic adjustment process
Solution Approach 2:
The system changes the physical state of the support structure from rigid to flexible, enabling the optical fiber array to adapt to various connector layouts and variations while maintaining manufacturing precision through controlled flexibility
3Manufacturing precision
If manual handling and termination of optical fibers is performed, then precision in fiber positioning is achieved, but labor costs and assembly time increase
Solution Approach 1:
The optical fibers are pre-positioned and secured on the flexible substrate before final connector assembly, allowing automated systems to perform the positioning task with high precision while reducing the need for manual intervention during the main assembly process
Solution Approach 2:
The flexible substrate with rigid fiber support enables the fiber array to self-align and self-position during automated assembly, eliminating the need for manual positioning while maintaining high precision through the inherent structural properties of the flexible circuit
Data Source
AI summary
A double flexible optical circuit includes: a flexible substrate supporting a plurality of optical fibers; a first connector terminating the optical fibers at a first end of the double flexible optical circuit; and a second connector terminating the optical fibers at a second end of the double flexible optical circuit. Each of the optical fibers is positioned in one of a plurality of separate extensions formed by the flexible substrate as the optical fibers extend from the first connector to the second connector. The first and second connectors are configured to be tested when the first and second connectors are connected through the double flexible optical circuit. The double flexible optical circuit is configured to be divided in half once the testing is complete to form two separate flexible optical circuits.