Reconfigurable Waveguide Blocks for Modular Fiber Shuffle
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Solution Overview
Problem
Conventional fiber shuffle assemblies in optical systems are expensive, labor-intensive, and inflexible, with fixed connectivity and high variability, leading to increased costs and project delays due to mis-sized fibers and complex assembly processes.
Innovation Solution
The use of reconfigurable waveguide (RWG) block assemblies with self-aligned simplex-fiber ferrules and fixed waveguides allows for modular and customizable optical signal shuffling, reducing part variability and enabling fast reconfiguration without the need for extensive reassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional fiber shuffle assemblies are used, then optical fiber cross-connecting is achieved, but the system becomes expensive and labor-intensive with fixed connectivity
Solution Approach 1:
The fiber shuffle assembly is divided into modular segments: a base unit with waveguide array and multiple interchangeable ferrule cartridges. Each cartridge contains pre-terminated fibers in specific shuffle patterns. This segmentation allows different connectivity configurations to be achieved by simply swapping cartridges rather than reassembling the entire assembly, reducing labor and enabling reconfigurability.
Solution Approach 2:
The base unit with waveguide array is designed as a universal platform that can work with multiple different ferrule cartridges, each providing different fiber shuffle patterns. This multi-functionality allows a single base unit to support various connectivity configurations (e.g., different cross-connect patterns, fan-out ratios) by changing only the ferrule cartridge, thereby reducing overall system complexity while maintaining adaptability.
2Manufacturing precision
If conventional fiber shuffle assemblies with fixed connectivity are used, then assembly is completed, but part variability increases leading to mis-sized fibers and project delays
Solution Approach 1:
Fiber shuffles are pre-configured and pre-terminated in the ferrule cartridges during manufacturing with precise length matching. The cartridges are designed with standardized mechanical interfaces and length tolerances. This preliminary action ensures that when cartridges are installed, the fiber lengths are already optimized for the specific shuffle pattern, eliminating on-site adjustments and preventing mis-sized fiber issues that cause delays.
3Adaptability or versatility
If complex fiber shuffles are implemented for high-density optics, then cross-connecting capability is achieved, but cost increases
Solution Approach 1:
Multiple fiber connections are merged into integrated ferrule cartridges where multiple fibers are bundled and terminated together in a single modular unit. The waveguide array in the base unit provides integrated routing paths. This merging eliminates the need for separate connector stages and intermediate fiber runs that would otherwise be required for complex shuffles, reducing the quantity of fiber and connectors needed while maintaining full cross-connecting capability.
Data Source
AI summary
Systems and assemblies are provided for reconfigurable waveguide (RWG) blocks having fixed waveguides therein. The RWG blocks can receive multiple self-aligned simplex ferrules to achieve customized fiber shuffles that are reconfigurable. A RWG block assembly includes the RWG block with fixed waveguides, a parallel-fiber ferrule interface to install a parallel-fiber ferrule, a plurality of simplex ferrule interfaces to install one or more simplex ferrules which allows the simplex ferrules to be positioned modularly within the RWG block assembly. The fixed waveguides allow optically coupling between the parallel-fiber ferrule and the one or more simplex ferrules via the RWG block. An assembly can also include a RWG block housing with the RWG block installed therein, and a carrier bracket coupled to the RWG block housing that receives a plurality of simplex ferrules such that each of the plurality of simplex ferrules can be positioned modularly and self-aligned within the carrier bracket.