Staggered Cleave Optical Connector for Expanded Beam Alignment
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Solution Overview
Problem
Current expanded beam multiple fiber connectors limit the beam diameter to match the fiber ribbon pitch, requiring manual splitting of fibers for connections with a diameter greater than the pitch, and are sensitive to contamination.
Innovation Solution
An optical connector design featuring an optically transmissive substrate with staggered microlenses and angle-cleaved optical waveguide ends, allowing for beam redirection and expansion without fiber splitting, and incorporating alignment features for robustness against contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the beam diameter is increased to be greater than the fiber pitch, then the connector becomes less sensitive to contamination and dust, but current connectors require manual splitting of fiber ribbons which increases complexity and labor
Solution Approach 1:
The invention divides the fiber ribbon into multiple rows with staggered cleave positions, allowing different rows to have different beam diameters. This segmentation enables the beam diameter to exceed the fiber pitch without requiring manual splitting, as the staggered arrangement naturally creates expanded beam paths for multiple fibers simultaneously.
Solution Approach 2:
The invention introduces a staggered arrangement in the transverse dimension, where fibers are offset from one another rather than aligned in a single row. This dimensional change allows the beam to expand beyond the original fiber pitch while maintaining connection to the intact fiber ribbon, eliminating the need for manual splitting.
2Manufacturing precision
If multiple fiber ribbons are connected using traditional methods, then fiber alignment can be achieved, but the process requires manual splitting which increases time and labor requirements
Solution Approach 1:
The fiber ribbons are pre-cleaved at staggered positions before connector assembly. This preliminary action of staggered cleaving enables automatic alignment when the connectors are mated, eliminating the need for time-consuming manual splitting and alignment operations during installation.
Solution Approach 2:
The staggered cleave design enables the connector to self-align multiple fiber ribbons automatically when mated. The offset cleave positions create complementary geometries that guide the fibers into proper alignment without requiring manual intervention, making the system self-servicing for alignment purposes.
3Device complexity
If a single row of fibers is used, then the connector design is simpler, but the beam diameter is limited to match the fiber pitch which increases sensitivity to contamination
Solution Approach 1:
The invention transitions from a single-row configuration to a multi-row staggered configuration. This dimensional change allows the beam diameter to expand beyond the fiber pitch while maintaining a relatively simple connector design, as the staggered arrangement is achieved through cleave geometry rather than complex mechanical structures.
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
Enables efficient, compact, and reliable connections of optical fiber ribbons with a beam diameter greater than the fiber-to-fiber pitch, while providing improved resistance to contamination and reduced transmission losses.
Implementation Method 1
each angle cleaved end face of an optical waveguide in the plurality of optical waveguides corresponding to a different microlens and being oriented so that light exiting each optical waveguide is directed by the angle cleaved end face to the corresponding microlens through the substrate
Implementation Method 2
an opposing second major surface comprising a plurality of microlenses staggered relative to one another
Data Source
AI summary
The disclosure generally relates to sets of optical waveguides such as optical fiber ribbons, and fiber optic connectors useful for connecting multiple optical fibers such as in optical fiber ribbon cables. In particular, the disclosure provides an efficient, compact, and reliable optical fiber connector that incorporates an optically transmissive substrate combining the features of optical fiber alignment, along with redirecting and shaping of the optical beam.