Single-Channel Expanded Beam Connector for Backplane Applications
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Solution Overview
Problem
Conventional expanded beam optical connectors are not suitable for single-channel applications due to their fixed channel configuration, which limits cable branching and results in a larger form factor, making them unsuitable for backplane and similar applications.
Innovation Solution
A single-channel expanded beam connector design that aligns optical components, such as ferrules and lenses, within a compact cylindrical sleeve, allowing for precise optical alignment and a smaller form factor without the need for alignment pins or adapters, enabling independent cable branching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-channel expanded beam connector is used, then optical performance and alignment stability are improved, but the connector cannot be used for single-channel applications requiring independent cable branching
Solution Approach 1:
The connector is divided into discrete optical subassemblies, each containing a ferrule and lens aligned within a cylindrical sleeve. This segmentation allows the connector to be configured for single-channel applications while maintaining the alignment stability typically achieved in multi-channel designs, as each subassembly can independently branch cables.
2Manufacturing precision
If alignment pins and spring force are used to maintain optical alignment, then alignment precision is improved, but the connector form factor increases
Solution Approach 1:
The alignment pins and spring force mechanisms are extracted from the connector design. Instead, optical alignment is achieved by containing the ferrule and lens within a cylindrical sleeve where their concentricity naturally maintains precise alignment, eliminating the need for additional alignment components and reducing the overall form factor.
3Volume of moving object
If a compact cylindrical sleeve design is used to hold optical components, then the connector form factor is reduced, but maintaining optical alignment becomes more difficult
Solution Approach 1:
The cylindrical sleeve is designed with specific local qualities: it provides concentric containment for the ferrule and lens, ensuring that components with good concentricity achieve automatic optical alignment. This localized structural quality maintains alignment precision while achieving a compact form factor without requiring additional alignment mechanisms.
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 design achieves reliable optical coupling with low insertion loss and a compact form factor, suitable for applications requiring flexible optical interfaces and reduced reflective loss, such as backplane connectors.
Implementation Method 1
The ball lens serves to expand and collimate light through (or near) the connector interface
Implementation Method 2
a lens at a mating end of the insert housing optically connected to the fiber, wherein the lens is configured to expand and collimate light
Implementation Method 3
a ferrule assembly contained within the insert housing and adapted to receive a fiber
Implementation Method 4
transmits the beam over an air gap between the connectors
Data Source
AI summary
A single-channel, expanded beam connector having a front and rear orientation and comprising: (a) a housing; (b) an outer sleeve at least partially contained by the housing; (c) a first inner sleeve disposed at least partially in the outer sleeve; (d) a ferrule disposed at least partially in the first inner sleeve; (e) a lens disposed at least partially in the first inner sleeve in front of the ferrule, wherein the lens and the ferrule have about the same outside first diameter which is just slightly less than that of the inside diameter of the first inner sleeve such that the ferrule and the lens are held in optical alignment in the first inner sleeve, and wherein the distal end of the outer sleeve extends beyond the inner sleeve to receive a second inner sleeve of a mating structure, the first and second inner sleeves having the same diameter which is just slightly less than the inside diameter of the outer sleeve such that the first and inner sleeves are aligned within the outer sleeve.