Flexible Optical Fiber Splitter Layout for Single-End Cylindrical Packaging
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Solution Overview
Problem
Existing optical fiber splice trays and splitters occupy significant space and require access to both ends for installation and servicing, complicating the management of high-density optical fiber connections.
Innovation Solution
A flexible substrate optical fiber splitter assembly that routes and secures optical fibers on a flexible substrate, allowing all fibers to enter or exit from a single end, with controlled bend radii to minimize bending losses, and can be rolled into a compact cylindrical package for protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional splice trays and splitters are used to manage optical fibers, then fiber connection and distribution functions are achieved, but the device occupies significant space and requires access to both ends for installation and servicing
Solution Approach 1:
The optical fiber bundle is segmented by separating one fiber from the remaining N-1 fibers, allowing independent routing paths. This segmentation enables the split tray to manage fibers in distinct sections, reducing overall space requirements while maintaining accessibility through single-end configuration
Solution Approach 2:
The invention transitions from linear fiber routing (requiring both ends) to a folded/dimensional arrangement where fibers are routed back through the same end. This dimensional change in fiber path configuration allows compact packaging while preserving full accessibility
2Volume of moving object
If optical fibers are routed with tight bends to achieve compact packaging, then space requirements are reduced, but bending losses increase
Solution Approach 1:
The flexible substrate provides localized support and controlled geometry at specific routing points, ensuring that bends maintain adequate radii where fibers are most vulnerable. This local quality control prevents excessive bending losses while achieving compact overall packaging
Solution Approach 2:
The invention changes the physical state and properties of the mounting substrate from rigid to flexible, allowing the fiber paths to be configured with optimal bend radii that minimize losses while achieving compact packaging. The flexible substrate enables parameter optimization of bend geometry
3Adaptability or versatility
If individual optical fibers are handled extensively for splicing and splitting operations, then fiber distribution and connection flexibility is improved, but the risk of fiber damage and breakage increases
Solution Approach 1:
The flexible substrate is pre-configured with designated routing paths and attachment points for fibers before actual fiber installation. This preliminary preparation allows fibers to be installed along predetermined safe paths, reducing handling complexity and damage risk while maintaining distribution flexibility
Solution Approach 2:
The flexible substrate acts as an intermediary mounting medium that secures fibers in controlled positions during installation and operation. This intermediary structure reduces direct handling of fragile fiber portions while enabling flexible routing and distribution configurations
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
The assembly provides a compact, robust, and efficient solution for optical fiber management, reducing space requirements and simplifying installation and servicing while maintaining low bending losses.
Implementation Method 1
One or more of the N optical fibers, the first optical fiber, the N−1 optical fibers, and M optical fibers are routed to result in a predetermined maximum bending loss
Data Source
AI summary
A flexible optical fiber splitter assembly and method of manufacture. The method can include separating, from an optical fiber bundle or ribbon comprising a plurality N of optical fibers, a first optical fiber to result in a first branch comprising the first optical fiber and a second branch comprising remaining N−1 optical fibers, splicing, to the first optical fiber, an input fiber of a 1×M splitter comprising M optical fibers as outputs, attaching and/or routing, to a flexible substrate, a portion of one or more of the optical fiber bundle or ribbon, the first optical fiber, the remaining N−1 optical fibers, and the 1×M splitter to a flexible substrate such that each enter or exit from a first end of the flexible substrate and align with furcations of a housing. The method can include rolling the flexible substrate into a cylinder and installing the flexible substrate into a cylindrical housing.