UDAT Optical Fiber Connector for Alignment Tolerance

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Solution Overview

Problem

Current optical fiber connectors are heavy, large, costly, susceptible to contamination, and sensitive to misalignments and temperature fluctuations, limiting their applications.

Innovation Solution

The development of an Ultra-Dense Alignment Tolerant (UDAT) optical fiber connector system using infinite conjugate imaging with pre-aligned and rigidly fixed hexagonally packed fiber bundles, which forms telecentric and alignment-tolerant interconnections, reducing sensitivity to contamination and misalignments while maintaining high coupling efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional optical fiber connectors are used, then reliable optical connection is achieved, but the connectors become heavy, large, and costly

Engineering Contradiction:

Improveoptical connection reliabilityVSAvoidconnector weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The connector is divided into multiple fiber bundles arranged in an array, with each bundle containing multiple individual optical fibers. This segmentation allows the system to maintain reliable optical connections through multiple parallel paths while reducing the overall size and weight compared to a single large connector assembly

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple fiber bundles are nested within a compact array structure, with fibers packed densely together. This nested arrangement maximizes the use of available space, reducing the overall connector footprint and weight while maintaining the reliability of individual optical connections

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If conventional optical fiber connectors are used, then optical connection is established, but the connectors become susceptible to contamination from dirt, dust, and cooling fluids

Engineering Contradiction:

Improveoptical connection reliabilityVSAvoidcontamination sensitivity

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The fiber array is enclosed in a protective housing with sealed interfaces that prevent contamination from dirt, dust, and cooling fluids. The housing acts as a barrier that protects the delicate optical fibers while allowing the connector to maintain its compact structure

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The connector design incorporates features that prevent contamination before it can affect the optical fibers, such as sealed housings and contamination-resistant materials, thereby maintaining reliability without requiring complex cleaning or maintenance procedures

Inventive Principle:

Principle #9Preliminary anti-action

3Reliability

If conventional optical fiber connectors are used, then optical connection is achieved, but the connectors are too sensitive to small misalignments or temperature fluctuations

Engineering Contradiction:

Improveoptical connection reliabilityVSAvoidalignment stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The connector incorporates flexible elements and compliant structures that allow the fiber array to dynamically adjust to misalignments and temperature changes. This dynamic capability maintains stable optical connections despite external disturbances, improving tolerance to alignment errors and environmental variations

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The connector design accounts for temperature fluctuations by using materials and structures with matched thermal expansion coefficients, thereby maintaining dimensional stability and optical alignment across a range of temperatures without requiring active compensation mechanisms

Inventive Principle:

Principle #35Parameter changes

4Productivity

If traditional optical interconnect systems are used, then optical signals are transmitted, but the systems are large and costly

Engineering Contradiction:

Improveoptical signal transmissionVSAvoidconnector size

Core Design Contradiction:

ProductivityVSArea of stationary object

Solution Approach 1:

Multiple optical fibers are merged into a single compact fiber array, with all fibers bundled together and integrated into one connector unit. This merging approach maintains high optical signal transmission capability while dramatically reducing the overall connector size compared to traditional separate fiber connector assemblies

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The fiber array utilizes three-dimensional packing and stacking arrangements to maximize fiber density within a compact volume. By organizing fibers in multiple dimensions rather than a simple linear arrangement, the system achieves high transmission capacity in a space-efficient configuration

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 UDAT connector system achieves efficient fiber coupling with high tolerance to misalignments and contamination, resulting in a compact, cost-effective, and reliable optical interconnect solution.

Implementation Method 1

an optical subsystem having a first end and a second end, the end portion of the array being operatively connected to the first end of the optical subsystem. Each optical fiber in the end section is capable of emitting electromagnetic radiation and the optical subsystem is capable of receiving the electromagnetic radiation emitted by each fiber and forming an image substantially at infinity

Methodology Applied

Scientific EffectInfinite conjugate imaging: Lens