Optical Connector Segmented Plug for Precision Alignment
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Solution Overview
Problem
Existing optical connectors face challenges in achieving high precision positioning due to deformation of alignment pins and difficulty in lowering the profile, as they require precise formation of the entire plug and are prone to external forces.
Innovation Solution
The optical connector design features a receptacle with an exposing opening and pin holes, and a plug with a protruding part and pins that are inserted into the receptacle, allowing for precise positioning without the need for high-precision formation of the entire plug, reducing the risk of pin deformation and enabling a lower profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the entire plug is fitted in the receptacle to connect optical waveguides and optical fibers, then positioning precision can be achieved, but manufacturing complexity and cost increase due to requiring high precision formation of the entire plug
Solution Approach 1:
The plug is segmented into a main body and a protruding part. The protruding part is inserted into the exposing opening of the receptacle to establish optical alignment, while the main body remains outside. This segmentation allows only the critical protruding part to be formed with high precision, reducing overall manufacturing complexity
Solution Approach 2:
The critical positioning function is extracted from the entire plug and concentrated in the protruding part. By taking out only the necessary portion (protruding part with optical transmission line end face) and inserting it into the receptacle's exposing opening, high positioning precision is achieved without requiring the entire plug to be high-precision
2Measurement precision
If alignment pins are used for positioning, then positioning can be achieved, but the pins are liable to deform due to external forces, compromising positioning precision
Solution Approach 1:
The alignment function is extracted from separate pins and integrated into the protruding part structure itself. The protruding part is directly inserted into the exposing opening to establish alignment, eliminating the need for separate pins that could deform under external forces
Solution Approach 2:
The alignment and optical transmission functions are merged into a single integrated protruding part. The protruding part both positions the optical transmission line and carries the optical signal, eliminating separate alignment pins that could deform
3Measurement precision
If alignment pins and engagement holes fit on the substrate, then positioning is achieved, but the profile cannot be lowered
Solution Approach 1:
The positioning approach transitions from substrate-plane fitting (engagement holes on substrate) to depth-direction insertion (protruding part inserted into exposing opening). This dimensional change allows the profile to be lowered while maintaining positioning precision through the exposed end face alignment
Data Source
AI summary
An optical connector has a receptacle which is fastened on a substrate provided with an optical waveguide, and a plug which holds an optical fiber and is positioned with respect to the receptacle. In the receptacle, an exposing opening for exposing an end face of the optical waveguide and a pin hole which opens in an opening direction of the exposing opening are provided. The plug has a facing surface facing the receptacle; a protruding part which protrudes from the facing surface, is formed integrally with the facing surface, exposes the an end face of the optical fiber on its front end face, and is inserted into the exposing opening; and the pin which is provided on the facing surface and is fitted in the pin hole. The front end face of the protruding part is located further toward an insertion direction side than a front end of the pin.