Unitary Optical Ferrule Stacking Alignment
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Solution Overview
Problem
The miniaturization of optical fiber devices has led to congestion management issues at optical interfaces and connection distribution points, requiring space-efficient and user-friendly multi-fiber connectors with precise alignment capabilities to maximize interconnection density and ease of use.
Innovation Solution
Unitary optical ferrules with registration features that allow for vertical or horizontal stacking, preventing sliding and ensuring alignment, while also incorporating apertures to manage light propagation and divergence, integrated into a housing with registration features for alignment within the connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multi-fiber connectors are miniaturized to increase interconnection density, then space efficiency is improved, but alignment precision becomes more difficult to maintain
Solution Approach 1:
The connector is divided into separate modular components including individual ferrules, a body housing, and distinct alignment features. Each ferrule can be independently manufactured and then assembled into the housing with precise alignment features that ensure proper positioning, allowing miniaturization without sacrificing alignment precision.
Solution Approach 2:
Alignment features such as registration protrusions and recesses act as intermediary elements between ferrules and the housing, or between mating connectors. These intermediary features facilitate precise alignment during assembly and operation, enabling small form factor design while maintaining the required alignment accuracy for optical fiber connections.
2Productivity
If ferrule structures are made smaller to realize space efficiency, then interconnection density is improved, but alignment functionality becomes more complex
Solution Approach 1:
Multiple alignment functions are merged into integrated alignment features that are formed as part of the housing structure or ferrule design. For example, registration features serve both as mechanical stops and alignment guides, combining multiple alignment functions into single structural elements, thereby reducing overall device complexity while maintaining high interconnection density.
Solution Approach 2:
The alignment features are designed to perform multiple functions simultaneously - providing mechanical registration, guiding lateral alignment, and ensuring proper orientation of mating connectors. This multi-functionality reduces the number of separate alignment mechanisms needed, simplifying the overall device structure while achieving high interconnection density.
3Ease of operation
If multi-fiber connectors are designed for plug-and-play capability, then ease of operation is improved, but manufacturing complexity increases
Solution Approach 1:
Alignment features and mechanical interlocking elements are pre-formed as integral parts of the ferrules and housing during the manufacturing process. Registration protrusions, recesses, and guiding features are created in advance through precision molding or machining, so that during final assembly the components simply snap together without requiring complex adjustment or alignment procedures, enabling plug-and-play operation while managing manufacturing complexity.
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 enables a compact, high-density optical connector system that maintains precise alignment and ease of use, enhancing the functionality and space efficiency of optical connections while ensuring reliable light propagation and alignment.
Implementation Method 1
an optical element for receiving light from an optical waveguide received and secured at the receiving area and changing at least one of a divergence and a propagation direction of the received light
Data Source
AI summary
A ferrule has a receiving area for receiving and securing an optical waveguide and an optical element for receiving light from an optical waveguide received and secured at the receiving area and changing at least one of a divergence and a propagation direction of the received light. A plurality of registration features are configured to permit a stacking of the ferrule in a stacking direction such that the ferrules in the stack are aligned relative to each other along a length of the ferrule and along a direction perpendicular to the stacking direction.