Rigid Optical Interconnect with Multi-Fiber and Edge Coupled Connectors

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Solution Overview

Problem

The increasing cost of optical connectors and alignment difficulties in miniaturized optical modules, such as transceivers, due to limited physical space and poor alignment tolerances in current flexible ribbon cables and lens arrays, necessitate a low-cost, compact, and accurately aligned optical interconnect solution.

Innovation Solution

A rigid optical interconnect device featuring a multi-fiber connector and an edge-coupled connector with a fiber array unit (FAU) and MPO ferrule, providing structural support and improved alignment tolerance through a compact design that includes guide pins and retainers, enabling mechanical and optical coupling of optical devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If flexible ribbon cables or lens arrays are used to couple optical devices, then optical signal transmission is enabled, but the physical space required increases and alignment precision deteriorates

Engineering Contradiction:

Improvephysical spaceVSAvoidalignment precision

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The patent combines the mechanical support function and optical alignment function into a single rigid connector structure. The connector housing provides both structural support and precise alignment features, eliminating the need for separate flexible cables or lens arrays that occupy additional space and require separate alignment processes.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces flexible mechanical cable systems with a rigid mechanical connector structure. This substitution eliminates the space requirements and alignment issues associated with flexible ribbons while maintaining the optical coupling function through a more stable, rigid framework.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Volume of moving object

If optical modules are miniaturized to reduce size, then space efficiency improves, but alignment tolerance deteriorates and manufacturing complexity increases

Engineering Contradiction:

Improvemodule sizeVSAvoidalignment tolerance

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The patent incorporates preliminary alignment features directly into the connector structure during manufacturing. Alignment pins, guide features, and pre-positioned fiber arrays are built into the connector housing, allowing alignment to be established before final assembly. This preliminary action ensures consistent alignment tolerance even in miniaturized modules where adjustment space is limited.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If traditional optical connectors are used, then optical coupling is achieved, but manufacturing cost increases and structural support is insufficient

Engineering Contradiction:

Improvestructural supportVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent designs the connector structure to perform multiple functions simultaneously: providing mechanical support for optical fibers, enabling precise alignment, facilitating easy connection and disconnection, and offering structural reinforcement. This multi-functionality eliminates the need for separate components, reducing manufacturing cost while improving structural support reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution reduces the size and manufacturing complexity of optical connectors, enhances alignment tolerance, and maintains good optical performance, making it suitable for miniaturized optical modules with reduced costs and improved durability compared to flexible connectors and lens arrays.

Implementation Method 1

a plurality of optical fibers disposed inside the multi-fiber connector and the edge coupled connector to optically couple the multi-fiber connector to the edge coupled connector

Methodology Applied

Scientific EffectTotal internal reflection: Total Internal Reflection

Data Source

PatentUS10732366B2Optical interconnect device including a multi-fiber connector and an edge coupled connector

Publication Date: 2020.08.04 WELLS FARGO BANK NA

AI summary

An optical interconnect device may include a multi-fiber connector at a first end of the optical interconnect device. The optical interconnect device may include an edge coupled connector at a second end of the optical interconnect device. The optical interconnect device may include a plurality of optical fibers disposed inside the multi-fiber connector and the edge coupled connector to optically couple the multi-fiber connector to the edge coupled connector, wherein the multi-fiber connector and the edge coupled connector rigidly interconnect to structurally support the optical interconnect device.