Optical Ferrule Alignment Structure Without Guide Pins
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Solution Overview
Problem
Existing optical fiber alignment techniques using guide pins require high dimensional accuracy and are prone to positioning errors due to foreign matter adherence, leading to increased connection loss.
Innovation Solution
An optical connection structure comprising a first and second ferrule with recessed or protruding portions and an adapter with matching protruding or recessed portions, allowing ferrules to be fitted without guide pins, ensuring precise alignment and preventing foreign matter interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If guide pins are used for aligning optical fibers, then alignment precision can be achieved, but the structure becomes complex and foreign matter can adhere to the guide pins causing positioning errors
Solution Approach 1:
The invention removes the guide pin component entirely from the optical connector structure. Instead of using separate guide pins for alignment, the patent integrates alignment functionality directly into the ferrule body through precisely formed recessed portions that mate with protruding portions on the adapter, thereby simplifying the overall structure while maintaining alignment precision.
Solution Approach 2:
The invention combines the alignment function and the fiber holding function into a single integrated ferrule structure. The recessed portions for alignment are formed directly on the ferrule body, merging what were previously separate components (guide pins and ferrule) into one unified structure, reducing complexity and potential sources of error.
2Manufacturing precision
If guide pins with high dimensional accuracy are used, then positioning accuracy improves, but manufacturing cost and difficulty increase
Solution Approach 1:
The alignment features (recessed portions) are integrated directly into the ferrule body as a single molded or machined structure rather than being separate precision components. This integration allows the alignment features to be manufactured simultaneously with the ferrule itself, reducing the need for separate high-precision manufacturing steps and assembly operations.
Solution Approach 2:
The invention divides the alignment function into multiple discrete recessed portions (first and second recessed portions) that are distributed around the ferrule circumference. This segmentation allows each recessed portion to be formed with standard precision during ferrule manufacturing, avoiding the need for ultra-high precision on a single centralized guide pin structure.
3Reliability
If guide pin insertion holes are provided in ferrules, then alignment can be achieved, but foreign matter can adhere in the holes causing connection loss
Solution Approach 1:
The invention eliminates the guide pin insertion holes that were present in conventional ferrules. By removing these holes and replacing them with external recessed portions on the ferrule surface, the patent prevents foreign matter from becoming trapped in deep cavities during connection and disconnection operations, thereby improving reliability.
Solution Approach 2:
Instead of having protruding guide pins that insert into holes (conventional approach), the invention inverts the geometry to have recessed portions on the ferrule that receive protruding portions on the adapter. This inversion prevents foreign matter from being trapped in the ferrule, as the recessed portions are open to the exterior and do not form enclosed cavities like insertion holes do.
Data Source
AI summary
An optical connection structure including a first ferrule, a second ferrule, and an adapter is disclosed. The first ferrule includes a distal end portion where a first light incidence/emission unit is formed. The second ferrule includes a distal end portion where a second light incidence/emission unit is formed. Each first side surface of both the ferrules is provided with a recessed portion or a protruding portion, and each second side surface of both the ferrules is provided with a recessed portion or a protruding portion. The adapter has an inner surface provided with a protruding portion or a recessed portion, and a protruding portion or a recessed portion. Both the ferrules are fittable into the adapter such that the first and second light incidence/emission units are optically connected each other while the distal end portions of both the ferrules face each other at a predetermined distance separated from each other.