Miniature Robust Hybrid Connector

To address the Navy's need for a miniaturized hybrid fiber optic/copper circular connector for use in the Buoyant Cable Antenna system, Physical Optics Corporation (POC) developed, in Phase I, a new Miniature Robust Hybrid Connector (MiRHyC) that provides 4 electrical contacts for 2 sets of twisted pair wires, 1-2 single-mode fiber optic contacts, and 1 RG-384 compatible coaxial contact in a single robust circular connector that is waterproof to a pressure of>1,050 psi, has a mated tensile strength of>350 lb, and is insensitive to mechanical shock and vibration. To date, POC designed the complete MiRHyC, including housing, dielectric inserts, and electrical and optical contacts. This design was validated using finite element analysis and optical simulation. A housing prototype with an outer diameter of 0.625 in. and mated length (excluding strain relief) of 1.25 in. was fabricated, mounted onto hybrid cables, and tested to withstand>364 lb of tensile load. In Phase II and Phase II Option, POC will optimize the MiRHyC design; assemble and test prototypes; conduct validation tests and demonstrate a technology readiness level>6; develop a preliminary production method; and deliver>2 prototypes to the Navy as per SPAWAR's letter requesting a revised Phase II proposal.