Optical Ferrule Alignment via Interlocking Recessed Portions
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Solution Overview
Problem
Optical connectors face challenges in maintaining constant forward and normal forces during mating without causing stress in optical fibers and their bonding, particularly due to the bending required to achieve alignment.
Innovation Solution
The use of optical ferrules with a unitary or separate piece construction, featuring a front portion that extends from a rear portion with an attachment and light redirecting element, and discrete retainers that apply resilient forces to maintain alignment without fiber bending, ensuring constant mating forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If bending is used to achieve alignment during mating, then alignment can be achieved, but stress is caused in optical fibers and their bonding
Solution Approach 1:
The patent introduces an intermediary mechanism - the ferrule structure with built-in alignment features and resilient retainers - that mediates between the mating process and the optical fibers. The ferrule's front portion extending into the recessed portion of the mate creates a mechanical intermediary that guides alignment without requiring fiber bending, while the resilient retainer provides a secondary intermediary force to maintain alignment constantily without stress on the fibers.
Solution Approach 2:
The patent replaces the conventional mechanical system of bending fibers to achieve alignment with a new mechanical system based on the ferrule's geometric features. The front portion extending into the recessed portion creates a mechanical interference fit that inherently provides alignment, substituting the need for fiber bending with a structural design that maintains fibers in a stress-free state while achieving the same alignment function.
2Reliability
If constant forward and normal forces are applied during mating, then reliable connection is achieved, but fiber stress and bonding issues occur
Solution Approach 1:
The patent segments the force application mechanism into distinct functional components: the resilient retainer applies the constant normal force, while the front portion extending into the recessed portion provides the forward alignment force. This segmentation allows the forces to be applied through the ferrule structure rather than directly on the fibers, maintaining connection stability while preventing fiber stress.
Solution Approach 2:
The ferrule structure serves as an intermediary that transmits and distributes the constant forces applied during mating. The resilient retainer and the geometric fit of the front portion into the recessed portion work together to apply forces through the ferrule body, which then transmits these forces to the optical connection interface without concentrating stress on the fibers or their bonding.
3Stability of the object's composition
If discrete retainers with resilient portions are used, then constant mating forces are maintained, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into the discrete retainer structure: the resilient portion provides the constant normal force, the through opening allows for assembly and force transmission, and the overall retainer structure maintains the mating connection. By combining these functions into a single integrated component rather than separate elements, the design achieves constant mating forces while minimizing the increase in device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution effectively maintains optical fiber alignment and reduces stress on the fibers and their bonding, ensuring reliable and stable connections while preventing accidental opening and stray light issues.
Implementation Method 1
Each of the first and second discrete retainers includes a resilient portion resiliently forcing the front portion of one of the first and second mated ferrules against the other one of the first and second optical ferrules
Implementation Method 2
The top side further includes a light redirecting portion for changing a direction of light received from an optical waveguide received and secured in the attachment portion
Data Source
AI summary
An optical connector assembly includes first and second optical ferrules. Each of the first and second optical ferrules includes a front portion extending forwardly from a rear portion. The rear portion includes a top side and a bottom side. The bottom side of the rear portion defines a recessed portion. The first and second optical ferrules mate with each other such that the front portion of each of the first and second ferrules is disposed in the recessed portion of the other one of the first and second ferrules. Discrete retainers are assembled to opposite ends of the mated first and second ferrules. Each of the retainers defines a resilient portion resiliently forcing the front portion of one of the first and second mated ferrules against the other one of the first and second optical ferrules.