Reflective Optical Connector Structure for Precise Fiber Alignment
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Solution Overview
Problem
Existing optical connectors face challenges in efficiently aligning multiple optical devices and fibers for optimal communication channels, often requiring complex structures that complicate assembly and alignment processes.
Innovation Solution
An optical connector design featuring a reflective injection-molded part mounted directly on a silicon substrate, utilizing alignment guides and a simplified structure that eliminates the need for printed circuit boards, ensuring precise alignment of optical devices and fibers through front and rear alignment guides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mechanical coupling device is used to maintain alignment between ferrules, then alignment precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the mechanical coupling device from the connector structure, extracting the alignment function to rely solely on ferrule precision and housing guidance features. This eliminates unnecessary complexity while maintaining alignment through precise ferrule positioning and housing geometry rather than additional mechanical components.
Solution Approach 2:
The housing structure is designed to perform multiple functions: it provides mechanical support, guides ferrule insertion, maintains alignment, and protects internal components. By integrating these functions into the housing and ferrule design rather than using separate specialized components, the patent reduces overall device complexity while achieving precise alignment.
2Reliability
If a mechanical coupling device is added to maintain ferrule alignment, then connection reliability is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent eliminates the mechanical coupling device, simplifying the manufacturing process. Alignment reliability is achieved through precision-machined ferrules and housing features that can be manufactured using standard precision machining processes, avoiding the need to manufacture and assemble additional coupling components.
Solution Approach 2:
The alignment function is merged into the ferrule and housing design itself, rather than being a separate function requiring additional components. The housing includes integrated guidance features and positioning structures that work with the ferrules to ensure alignment, reducing the number of parts and manufacturing steps required.
3Stability of the object's composition
If a mechanical coupling device is used to maintain alignment, then alignment stability is improved, but device complexity increases
Solution Approach 1:
The patent removes the mechanical coupling device that would otherwise provide alignment stability. Instead, stability is achieved through the rigid housing structure, precise ferrule positioning features, and interference-fit connections between components, eliminating the need for additional alignment-maintaining mechanisms.
Solution Approach 2:
The housing and ferrules include asymmetric positioning features such as tapered surfaces, asymmetric grooves, and keyed structures that ensure correct orientation and stable alignment during insertion and operation. These asymmetric features prevent misalignment and maintain stable connections without requiring symmetric mechanical coupling devices.
Data Source
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AI summary
An optical connector includes: a base substrate; an optical device on the base substrate; an optical fiber optically aligned with the optical device; and a reflective injection-molded part arranged on the base substrate to cover the optical device and providing a reflective surface in an optical path between the optical device and the optical fiber, wherein the reflective injection-molded part includes: a prism providing the reflective surface; an alignment leg supporting the prism in a state in which the prism is at a height from the base substrate; a main block on a side of the prism, the side of the prism being opposite the base substrate; and a plurality of support ribs branching off at intermittent positions along the main block and supporting the prism with respect to the main block.