Optical Ferrule Protrusion Recess Alignment
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Solution Overview
Problem
Current multi-fiber ferrule connectors require all fibers to be on the same plane and use large alignment pins for core-to-core alignment, which consumes ferrule space and limits fiber density.
Innovation Solution
The use of a mated pair of optical ferrules with protrusions and recesses allows for optical alignment and connection of fibers without the need for fibers to be on the same plane, using a configuration where protrusions from one ferrule insert into recesses of another, enabling face-to-face optical alignment and connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If large alignment pins are used for core-to-core alignment, then alignment precision is improved, but ferrule space is consumed
Solution Approach 1:
The patent transitions from using large-diameter alignment pins in a traditional planar arrangement to a three-dimensional configuration where alignment features are distributed across multiple planes and depths within the ferrule structure. This dimensional change allows precise alignment without requiring large lateral space, as the alignment function is achieved through vertical and radial positioning rather than only lateral pin insertion.
Solution Approach 2:
The alignment features are nested within the ferrule structure itself, with alignment protrusions and recesses integrated into the ferrule body rather than requiring separate large pins. The alignment mechanism is contained within the ferrule volume, similar to nested dolls, achieving alignment functionality without external space-consuming components.
2Ease of manufacture
If all fibers are placed on the same plane, then manufacturing simplicity is improved, but fiber density is limited
Solution Approach 1:
The patent arranges optical fibers in a three-dimensional configuration rather than constraining them to a single plane. Fibers are positioned at different heights and radial distances from the ferrule center, creating a volumetric fiber layout. This multi-planar arrangement significantly increases the number of fibers that can be accommodated within the same ferrule envelope while maintaining manufacturability through systematic positioning.
Solution Approach 2:
The patent employs adjustable and reconfigurable fiber positioning mechanisms that allow fibers to be dynamically positioned and secured at optimal locations within the ferrule. This dynamic approach enables flexible fiber arrangement in three-dimensional space, maximizing fiber density while accommodating manufacturing tolerances and enabling post-assembly adjustments.
Data Source
AI summary
A pair of optical ferrules is disclosed. Each of a first ferrule and a second ferrule of the pair may include at least one protrusion and at least one recess. Each of the protrusions or recesses may have at least one channel for holding an optical fiber. Upon mating the two ferrules, the protrusion of the first ferrule is configured to be inserted into the recess of the second ferrule and the protrusion of the second ferrule is configured to be inserted into the recess of the first ferrule such that the optical fibers held in each protrusion are optically aligned to be connected face to face with the optical fibers held in the corresponding recess of the other ferrule.