Tunable Optical Fiber Connectors for Core-Ferrule Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing optical fiber connectors and cable assemblies face inefficiencies and increased costs due to the need for exposing a substantial portion of the ferrule to measure core-ferrule concentricity, which is essential for minimizing optical loss, especially in harsh environments where connectors are used.
Innovation Solution
A tunable cable assembly design featuring a connector sub-assembly with a rotatable ferrule holder and retention body, allowing for selective angular orientation within a housing assembly, which includes two shells and a crimp section, enabling precise positioning to enhance coupling efficiency while preventing longitudinal movement, thus facilitating accurate core-ferrule concentricity measurement and adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the inner housing covers substantially all of the ferrule length, then the connector structure is compact and protected, but the ferrule surface is not exposed for measuring core-ferrule concentricity
Solution Approach 1:
The ferrule is divided into two segments: a covered portion supported by the inner housing and an exposed portion extending beyond the inner housing. This segmentation allows the measurement function to be performed on the exposed portion while the covered portion maintains structural protection, resolving the contradiction between measurement access and structural integrity.
Solution Approach 2:
The solution moves the measurement function from the longitudinal dimension (requiring ferrule exposure along its length) to the angular dimension (allowing measurement of the exposed ferrule surface at specific orientations). The ferrule holder can be rotated to position the exposed ferrule surface for measurement while maintaining compact housing coverage.
2Measurement precision
If the ferrule is exposed for measurement, then core-ferrule concentricity can be measured, but the connector is less protected in harsh environments
Solution Approach 1:
The ferrule is segmented into a protected portion (covered by inner housing) and a measurement portion (exposed). The protected portion maintains environmental shielding while the exposed portion enables measurement functionality, resolving the contradiction between measurement access and environmental protection.
Solution Approach 2:
The ferrule is pre-configured with an exposed portion that extends beyond the inner housing before final assembly. This preliminary configuration allows measurement to be performed during assembly without requiring the ferrule to be fully exposed during operation, maintaining protection while enabling measurement.
3Stability of the object's composition
If the ferrule holder is fixed to prevent movement, then the connector is stable, but the ferrule cannot be rotated for tuning
Solution Approach 1:
The ferrule holder is designed with dynamic characteristics: it is fixed relative to the inner housing to provide stability during normal operation, but can be rotated relative to the housing to enable tuning. This dynamic design allows the system to transition between stable and adjustable states as needed.
Solution Approach 2:
The retention body is segmented into features that provide longitudinal fixation (preventing movement along the axis) while allowing rotational movement. This segmentation of constraints enables stability in one dimension while maintaining adaptability in another dimension.
4Area of stationary object
If the inner housing is designed to cover the ferrule, then the connector is compact, but the ferrule surface area for measurement is reduced
Solution Approach 1:
The ferrule surface is segmented into a covered area (providing compactness) and an exposed area (providing measurement surface). This segmentation allows the housing to maintain compact coverage while preserving sufficient exposed surface area for measurement functions.
Solution Approach 2:
The ferrule holder and housing are designed with asymmetric configurations that create specific exposed portions on the ferrule. This asymmetric design ensures adequate measurement surface area while maintaining overall compactness, resolving the contradiction between coverage and measurement area.
Data Source
AI summary
A tunable connector formed from a connector sub-assembly, a housing an an outer housing is disclosed. The connector sub-assembly has an inner housing, a ferrule held by a ferrule holder and a retention body. The housing is formed from two shells that define a longitudinal passageway that supports a portion of an optical fiber cable to define cable assembly. The longitudinal passageway has a front-end section that supports a section of the retention body to inhibit longitudinal movement but to allow for rotation of the retention body and thus the connector sub-assembly to a select orientation. An outer housing operably disposed over the inner housing inhibits rotation of the retention body and thus the connector sub-assembly once an orientation is selected. Connector and cable sub-assemblies and assemblies, as well as a method of tuning the tunable connector, are also disclosed.