Manufacturing method of insertion core suitable for CPO technology, insertion core and mold

Abstract

The invention relates to a manufacturing method of an insertion core suitable for a CPO technology, the insertion core and a mold, the thickness of the insertion core is successfully reduced to 1.25 mm and the width of the insertion core is optimized to 7mm through the design of an integrally formed ultrathin flat body and a reinforcing rib structure, so that the insertion core can be easily embedded into an extremely limited space in CPO packaging and is arranged close to an ASIC chip and an optical engine, and the manufacturing cost is reduced. The space utilization rate and the integration density of CPO packaging are greatly improved, and the packaging structure is conveniently suitable for a core with higher functional density. The V-shaped groove collectively positions the mold needle in the mold, so that the accumulated position error of the whole row of holes is smaller under the condition that the distance between 36 optical fiber holes is 127 microns, each optical fiber can be axially aligned with a corresponding waveguide on a silicon optical chip, and extremely low and uniform insertion loss is brought. Through cooperation of guide holes at two ends of the insertion core and external guide pins, submicron precision butt joint with a butt joint port on a CPO optical engine is realized, signal integrity of a high-speed parallel optical link is guaranteed, and requirements of a CPO system of 1.6 T and above for consistency and stability of optical coupling are satisfied.

Description

Technical Field

[0001] This application relates to the field of ferrule manufacturing methods, ferrules and molds, and more particularly to a ferrule manufacturing method, ferrule and mold suitable for CPO technology. Background Technology

[0002] With the rapid development of cloud computing, artificial intelligence, and hyperscale data centers, data traffic is experiencing explosive growth. To address this challenge, the bandwidth of data center network switches is evolving from 800G to 1.6T, 3.2T, and even higher speeds. Against this backdrop, co-packaged optics (CPO) technology is widely regarded as a core solution for next-generation high-speed interconnects due to its ability to significantly reduce system power consumption, latency, and physical size. However, the standard multi-core fiber ferrules widely used in the industry (such as the MT series) were not originally designed for the extreme harshness of CPO environments. Therefore, their application in CPO exposes a series of unresolved technical issues.

[0003] Firstly, there's the conflict between physical size and integration density. Traditional MT ferrules typically have a large thickness and width to maintain mechanical strength and pin hole stability. However, CPO packaging space is extremely valuable, and the optical engine must be placed within millimeters of the ASIC chip. The large size of traditional ferrules encroaches on the limited packaging space, interferes with layout, and directly conflicts with the fundamental goal of CPO—ultra-compactness and high integration. Existing ferrules struggle to achieve a "mini" and "ultra-thin" form factor while maintaining a high channel count.

[0004] Secondly, the extreme challenges of channel density and alignment accuracy mean that increasing the number of fibers in a single row is an inevitable trend to improve overall bandwidth. However, when the number of fibers increases to 36 or even higher, while maintaining the standard center-to-center distance of 127 μm, the overall width of the ferrule increases, placing extreme demands on the uniformity of the ferrule material and the processing precision. Existing technologies and structures struggle to maintain consistently sub-micron (<0.7 μm) positional accuracy for all 36 80 μm fiber holes in such a long single-row structure. Micron-level cumulative errors can lead to misalignment between the fiber and silicon waveguide in the edge channels, causing a surge in insertion loss and deterioration of channel uniformity, severely impacting system performance.

[0005] However, existing technologies face significant manufacturing bottlenecks in producing high-channel-count (e.g., 36 cores and above), ultra-thin (e.g., thickness ≤ 1.25 mm), and sub-micron-level fiber aperture positioning accuracy fiber ferrules suitable for CPO technology. Specifically:

[0006] Precision is difficult to guarantee: During the injection molding process, the die needle used to form micro-fiber holes (such as Φ80μm) is prone to bending, displacement or vibration due to the uneven impact of the plastic melt, resulting in the cumulative error of the hole position in the final product far exceeding the accuracy requirement of ±0.7μm.

[0007] The contradiction between strength and size: In order to achieve an ultra-thin structure (such as 1.25mm thickness), the thickness of the mold pin fixing plate must also be reduced accordingly. This weakens its rigidity and makes it prone to deformation under high injection pressure, further amplifying the positional error of the mold pin. It is difficult to ensure both the mechanical strength and molding accuracy of the core at the same time.

[0008] Poor process stability: Traditional "single-point fixing" or "small-area fixing" methods for die pins cannot effectively limit the displacement of die pins in multiple degrees of freedom, resulting in large dispersion of product accuracy between different production batches or even within the same batch, low yield, and failure to meet the consistency and reliability requirements of key components for large-scale commercialization of CPO technology.

[0009] Therefore, existing technologies lack a fiber optic ferrule that can simultaneously meet the requirements of ultra-high density, ultra-thin structure, ultra-high alignment accuracy, excellent thermal stability, and secure mating interface. This has become a key bottleneck restricting the large-scale commercialization of CPO technology. Therefore, there is an urgent need in this field for an innovative ferrule solution to overcome these shortcomings. Summary of the Invention

[0010] The technical problem this application aims to solve is that existing ferrules are difficult to guarantee in terms of accuracy when applied to CPO technology, and there is a contradiction between strength and size, as well as poor process stability. To address the above-mentioned shortcomings of the prior art, this application provides a manufacturing method for a ferrule suitable for CPO technology, the ferrule itself, and a mold.

[0011] To solve the above-mentioned technical problems, the technical solution adopted in this application is:

[0012] A method for manufacturing a ferrule suitable for CPO technology is characterized by comprising the following steps:

[0013] Prepare a mold with multiple mold pin positioning grooves, wherein the multiple mold pin positioning grooves are arranged in a single row and are set in parallel;

[0014] Place the die needles in each set of die needle positioning slots so that they contact the positioning slot line and form a die needle array;

[0015] The moving mold and the fixed mold are closed to form the mold body by injection molding;

[0016] After the core body cools and solidifies, it is cleaned and annealed, and then demolded to obtain the formed core.

[0017] Inspect the fiber optic hole accuracy of the shaped ferrule.

[0018] Preferably, in the process of closing the mold by fitting the moving mold and the fixed mold together to form the insert body by injection molding, the method further includes:

[0019] The array material is dried to reduce its water content to a preset value and then heated to obtain the injection molding melt;

[0020] Under a first pressure value, at a first speed, molten plastic is injected into the mold to the first preset condition;

[0021] Once the first preset condition is met, the injection melt is injected at the second speed until the second preset condition is met.

[0022] Once the second preset condition is met, the speed is switched to the third speed and adjusted to the second pressure value. The pressure is maintained at the second pressure value for a preset time to complete the injection molding and obtain the ferrule body.

[0023] Preferably, the first preset condition is that the injection melt is adjusted from the first speed to the second speed after it passes around the mold tip;

[0024] The second preset condition is that the percentage of the injection melt filling the cavity reaches a preset value.

[0025] Preferably, the first speed and the third speed are less than the second speed, and the first pressure value is less than the second pressure value.

[0026] Preferably, the process of cleaning and annealing after the core body has cooled and formed, and then demolding to obtain the formed core, further includes:

[0027] Before the core body is demolded, the temperature difference between the moving mold and the fixed mold is controlled within a threshold range, and demolding is only performed when the temperature difference between the moving mold and the fixed mold is less than the threshold.

[0028] Preferably, the positioning groove of the mold needle is a V-shaped positioning groove or a precision hole, the groove spacing of the V-shaped positioning groove is 127.0±0.1μm, the V-angle of the V-shaped positioning groove is 90°±0.5′, the groove depth of the V-shaped positioning groove is 150μm, the cumulative spacing error of all the V-shaped positioning grooves is less than ±0.2μm, the diameter of the mold needle is 80.0±0.1μm, and the diameter of the precision hole is 80+0.50μm.

[0029] A ferrule suitable for CPO technology is constructed, characterized in that: it comprises a ferrule suitable for CPO technology manufactured by a manufacturing method for a ferrule suitable for CPO technology as described above, the ferrule comprising a ferrule body and a plurality of fiber optic holes disposed on the ferrule body, the plurality of fiber optic holes being arranged in a single row in parallel.

[0030] Preferably, guide holes are provided on both sides of the optical fiber hole, and there are 36 groups of optical fiber holes in total. The optical fiber holes in each group are of the same size and the hole diameter is 80+0.50μm. The cumulative center error of the 36 groups of optical fiber holes is less than ±0.7μm. The thickness of the ferrule body is 1.25mm and the width is 7mm.

[0031] A mold is constructed, characterized in that it is used in a method for manufacturing a ferrule suitable for CPO technology as described above, the mold comprising a moving mold and a fixed mold corresponding to the moving mold, both the moving mold and the fixed mold being provided with cavities, and the fixed mold being provided with multiple sets of parallel positioning grooves, wherein mold pins can be placed in the positioning grooves.

[0032] Preferably, the positioning groove is a V-shaped positioning groove, which is arranged in a single row in parallel. The groove spacing of the V-shaped positioning groove is 127.0±0.1μm, the V-angle of the V-shaped positioning groove is 90°±0.5′, the groove depth of the V-shaped positioning groove is 150μm, and the cumulative spacing error of all the V-shaped positioning grooves is less than ±0.2μm.

[0033] The beneficial effects of this application are as follows: the above method fundamentally guarantees product accuracy: by using the specific production method of "V-groove collective positioning die pin", the problem of the accuracy of 36 independent die pins that are difficult to control is transformed into a high-precision V-groove array. The latter is easier to achieve and control through modern ultra-precision machining technology, thereby ensuring at the methodological level that the final ferrule product can achieve the limit accuracy of cumulative position error of less than ±0.7μm.

[0034] This method significantly improves the stability and yield of the manufacturing process: it endows the mold pin array with extremely high overall rigidity, enabling it to resist interference in the injection molding process, greatly reducing the dispersion of product precision, making it possible to produce high-precision cores on a large scale and stably, and thus significantly improving the yield.

[0035] This method achieves a balance between product performance and production efficiency: while ensuring extremely high precision in ultra-thin cores (1.25mm), it does not sacrifice production efficiency or mold life. The rigid mold pin array reduces the frequency of maintenance and adjustments during production, improving the overall utilization rate of the equipment.

[0036] Through a one-piece, ultra-thin, flat body design and reinforcing rib structure, the ferrule thickness was successfully reduced to 1.25mm and the width optimized to 7mm while ensuring mechanical strength. This size allows it to be easily embedded in the extremely limited space within the CPO package, adjacent to the ASIC chip and optical engine layout, greatly improving the space utilization and integration density of the CPO package and clearing the way for higher functional density chip designs. Simultaneously, sub-micron alignment accuracy was achieved with an ultra-high number of channels. Thanks to the core technology of the "V-groove collective positioning mold pin" in the mold, this application achieved a cumulative positional error of less than ±0.7μm for the entire row of 36 fiber holes with a 127μm spacing, ensuring that each fiber can achieve near-perfect axial alignment with the corresponding waveguide on the silicon photonics chip, resulting in extremely low and uniform insertion loss. The insertion loss difference among all 36 channels was controlled within a very small range. The ferrule body, as a high-precision reference platform, uses its internal micro-hole array to collimate and fix multiple fibers. By using the guide holes at both ends of the ferrule to cooperate with the external guide pins (PINs), submicron-level precision docking with the docking port on the CPO optical engine is achieved, ensuring the signal integrity of the high-speed parallel optical link and meeting the consistency and stability requirements of optical coupling for 1.6T and above CPO systems. Attached Figure Description

[0037] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the present application will be further described below in conjunction with the accompanying drawings and embodiments. The drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0038] Figure 1 This is a schematic flowchart of a preferred embodiment of the manufacturing method of this application;

[0039] Figure 2 This is a detailed flowchart illustrating step S3 in the manufacturing method of a preferred embodiment of this application.

[0040] Figure 3 This is a schematic diagram of the ferrule structure according to a preferred embodiment of this application;

[0041] Figure 4 This is a schematic diagram of the mold structure according to a preferred embodiment of this application. Detailed Implementation

[0042] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, a clear and complete description will be provided below in conjunction with the technical solutions in the embodiments of this application. Obviously, the described embodiments are some embodiments of this application, but not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this application.

[0043] A preferred embodiment of the first aspect of this application provides a method for manufacturing a ferrule suitable for CPO technology; such as Figure 1 As shown, it includes the following steps:

[0044] S1: Prepare a mold with multiple parallel die pin positioning grooves;

[0045] Specifically, a precision injection mold is provided, comprising a fixed plate and a movable plate, and a cavity between the fixed and movable plates for forming the insert body. The fixed and movable plates are made of SKD61 hard mold steel, with an effective working thickness of 8mm to ensure sufficient rigidity. Then, 36 parallel V-grooves are fabricated on the working surface of the fixed plate using an ultra-precision steel cutting machine, laser processing, or micro-electrical discharge machining. This processing is carried out in a temperature-controlled workshop, with the temperature maintained at 20±0.1℃.

[0046] Furthermore, the parameters of each group of V-grooves meet the following requirements: groove spacing of 127.0 ± 0.1 μm, V-angle of 90° ± 0.5′, groove depth of 150 μm, and the cumulative spacing error of all V-grooves must be controlled within ± 0.2 μm. The cavity is a one-piece molded flat structure with a long, flat, strip-shaped appearance, and its dimensions meet the following requirements: thickness of 1.25 mm and width of 7 mm.

[0047] S2: Place mold needles in each group of mold needle positioning slots to form a mold needle array and place the guide needles in the guide slots;

[0048] Specifically, each set of V-grooves contains a mold pin. The mold pins are made of tungsten steel with a diameter of 80.0±0.1μm and a straightness error of less than 1μm / 50mm. Each of the 36 sets of mold pins is precisely placed into one of the V-grooves on the fixing plate. Because the 36 sets of V-grooves are arranged in parallel, the 36 mold pins are also placed in parallel, forming a collective positioning array. This collective positioning method transforms the 36 mold pins from discrete individuals into a unified, high-precision mold pin array. Simultaneously, the line contact provided by the V-grooves provides multi-segment, uniform support along the length of each slender mold pin, greatly enhancing the overall rigidity of the mold pin and effectively suppressing bending and displacement caused by melt impact during injection molding. This ensures that the positional accuracy of the mold pin array directly maps to the positional accuracy of the fiber optic hole array in the final product, thus guaranteeing high precision from the manufacturing stage. Furthermore, the V-groove positioning method of line contact, compared with the traditional point contact or small plane contact, can more effectively restrict the displacement of the mold pin in multiple degrees of freedom, ensuring that the parallelism and relative position of all mold pins do not drift during the injection molding process, thereby guaranteeing the position accuracy of the final core hole (cumulative error < ±0.7μm).

[0049] S3: Close the mold and perform injection molding to form the insert body;

[0050] Specifically, the movable plate and fixed plate are aligned and closed to shut the mold, ensuring that each mold pin is precisely clamped between the corresponding V-grooves of the fixed and movable plates, forming a rigid "pin grid" array. This pin array precisely passes through the corresponding positions within the cavity. Then, using optimized injection molding parameters, high-polymer PPS is injected into the cavity to form the insert body. The increased rigidity of the mold pins allows for a more optimized injection speed profile, reducing internal stress caused by uneven flow. This ensures sufficient material filling while preventing mold pin misalignment and product warping when molding ultra-thin insert bodies.

[0051] S4: After the core body cools and solidifies, it is cleaned and annealed, and then demolded to obtain the formed core.

[0052] S5: Inspect the fiber optic hole accuracy of the shaped ferrule;

[0053] Specifically, after the ferrule body cools and sets, the formed ferrule undergoes necessary post-processing, such as cleaning and annealing to eliminate internal stress. It is then removed from the mold. Thanks to the precise fixing and excellent rigidity of the mold pins, the mold pins are subjected to uniform force during demolding, making them less prone to damage and extending the mold's lifespan. Then, optical measurement settings are used to perform a full inspection of the fiber optic hole's positional accuracy.

[0054] Furthermore, during the cooling stage, the cooling time is set to 25 seconds. To avoid excessive temperature difference between the fixed and movable plates of the mold, which could cause internal stress, the temperature difference is controlled within ±3℃. This can be achieved by measuring the temperatures of the fixed and movable plates in real time and calculating the temperature difference. During the demolding stage, after mold opening, a robotic arm can be used to grip the product's sprue and smoothly remove the product from the mold pins. Due to the excellent rigidity of the mold pins and their mirror-polished surface, demolding is smoother, without whitening or deformation. In the precision inspection process, samples are taken from each production batch, and a high-precision optical image measuring instrument is used to scan and measure the positions of 36 fiber optic holes, ensuring that the cumulative positional error is consistently less than ±0.7μm to obtain a final, high-quality product.

[0055] Due to its one-time injection molding process, the ferrule body has a long, flat, strip-shaped shape with a thickness of 1.25mm and a width of 7mm. It features 36 fiber optic holes with a spacing of 127μm between each group, achieving a "mini-thin" characteristic. Simultaneously, along the length of the ferrule body, a single row of 36 parallel through-holes forms a fiber optic hole array. Each fiber optic hole has a diameter of 80±0.50μm to accommodate 80μm bare optical fibers, and the center-to-center distance of all fiber optic holes is precisely 127μm. Furthermore, the cumulative positional error of the centers of the 36 fiber optic holes is less than ±0.7μm, resulting in a high-precision fiber optic hole array. Two guide holes can be formed at each end of the ferrule body for precise positioning of the guide pins with the optical engine interface. The inner diameter tolerance of the guide holes is controlled within 0.50μm, forming the guide hole and positioning structure.

[0056] In step S3 above, where the mold is closed and injection molding is performed to form the ferrule body, the high-precision fiber optic ferrule is manufactured using an innovative precision injection molding process. The core of this process lies in the "V-groove collective positioning" technology of the mold pins and the corresponding injection parameter control, such as... Figure 2 As shown, the specific injection molding steps include:

[0057] S30: Dry the injection molding material to reduce its water content to a preset value and then heat it to obtain an injection melt;

[0058] S31: Inject the molten plastic into the mold at a first speed under a first pressure value until the molten plastic bypasses the mold pin;

[0059] S32: After the injection molten material flows past the tip of the mold needle, it is injected at a second speed until the cavity of the mold is filled to the preset value;

[0060] S33: Switch to the second pressure value and maintain pressure at the second pressure value for a preset time to complete the injection molding and obtain the insert body.

[0061] Specifically, before injection molding, glass fiber reinforced PPS (polyphenylene sulfide) is selected as the base material, with a glass fiber content of 70%. Before injection molding, the PPS is dried in a 120°C forced-air oven for more than 4 hours to reduce the moisture content to less than 0.02%. Then, it is heated to form a melt and a fully electric precision injection molding machine (clamping force ≥ 30 tons) is used. The repeatability of the injection unit is better than ±0.1%. The injection molding process adopts a multi-segment injection speed curve of "slow-fast-slow".

[0062] Furthermore, in the first stage, the melt is injected at a speed of 5 mm / s to allow it to smoothly pass over the die needle, preventing initial impact from causing die needle deviation; this is the slow stage. After the melt flows past the tip of the die needle, the second stage, the fast stage, begins, increasing the melt injection speed to 45 m / s to quickly fill 95% of the cavity. The melt front is then allowed to cool. It should be noted that there are no pressure requirements during the first and second stages; the pressure can be the same as air pressure. In the third stage, the injection speed is slowed down until the cavity is completely filled, and the pressure in the third stage is increased to 60 MPa to form a holding pressure. The holding pressure is maintained for 3 seconds to compensate for material shrinkage. After the holding pressure is completed, the injection molding is finished, and the core body is obtained. In this application, the first and third speeds can both be set to 5 m / s, while the second speed should be significantly greater than both the first and third speeds, set to 45 m / s. This allows the melt to smoothly bypass the mold pin using the first speed, preventing initial impact from causing module displacement. The second speed then rapidly fills the cavity to a preset value to prevent cooling of the melt front. Finally, the third speed completely fills the cavity to complete the injection molding. Simultaneously, the first pressure in the first and second stages is less than the second pressure in the third stage, thus preventing material shrinkage in the third stage. This results in an ultra-thin ferrule with a higher fiber hole density and extremely high ferrule precision, improving production efficiency and ensuring mold lifespan, while reducing the frequency of maintenance and adjustments during production. The resulting ferrule enables high-channel-count, high-precision, and high-reliability fiber array and optical chip interfacing within a limited packaging space and is suitable for CPO technology.

[0063] The above method fundamentally guarantees product precision: by employing the specific production method of "V-groove collective positioning die pins," the difficulty in controlling the precision of 36 individual die pins is transformed into the machining problem of a high-precision V-groove array. The latter is easier to achieve and control using modern ultra-precision machining technology, thus ensuring at the methodological level that the final ferrule product can achieve an ultimate precision of less than ±0.7μm in cumulative positional error.

[0064] This method significantly improves the stability and yield of the manufacturing process: it endows the mold pin array with extremely high overall rigidity, enabling it to resist interference in the injection molding process, greatly reducing the dispersion of product precision, making it possible to produce high-precision cores on a large scale and stably, and thus significantly improving the yield.

[0065] This method achieves a balance between product performance and production efficiency: while ensuring extremely high precision in ultra-thin cores (1.25mm), it does not sacrifice production efficiency or mold life. The rigid mold pin array reduces the frequency of maintenance and adjustments during production, improving the overall utilization rate of the equipment.

[0066] This application provides a preferred embodiment of a ferrule manufacturing method for CPO technology. The difference from Embodiment 1 is that the mold uses a single fixed plate with precision micro-holes to fix the mold pin. Thirty-six precision holes are laser-machined on the plate, each with the same dimensions as the V-groove. These precision holes allow for line contact with the mold pin, which is then fixed after passing through the plate, ensuring positional accuracy. Simultaneously, the ferrule body is injection molded through the cavity between the movable plate and the fixed plate. The specific injection molding steps are the same as in Embodiment 1 and will not be repeated here.

[0067] The preferred embodiment of the second aspect of this application provides a ferrule suitable for CPO technology. Since the ferrule product adopts all the technical solutions of the manufacturing method of the ferrule product of the above embodiments, it has at least all the beneficial effects brought about by the technical solutions of the above embodiments, and will not be described further here.

[0068] like Figure 3As shown, the ferrule 4 body has 36 sets of fiber optic holes 40 arranged in a single parallel row, and two sets of guide holes 41 are provided on both sides of the ferrule body. The ferrule body is 1.25mm thick and 7mm wide, achieving extremely compact integration. Through the one-piece molded ultra-thin flat body design and reinforcing rib structure, the ferrule thickness is successfully reduced to 1.25mm and the width optimized to 7mm while ensuring mechanical strength. This size allows it to be easily embedded in the extremely limited space within the CPO package, adjacent to the ASIC chip and optical engine layout, greatly improving the space utilization and integration density of the CPO package, and clearing the way for higher functional density chip designs. Simultaneously, submicron-level alignment accuracy was achieved with an ultra-high number of channels. Thanks to the core technology of the "V-groove collective positioning mold pin" in the mold, this application achieved a cumulative position error of less than ±0.7μm for the entire row of 36 fiber holes with a spacing of 127μm. This ensures that each fiber can achieve near-perfect axial alignment with the corresponding waveguide on the silicon photonic chip, resulting in extremely low and uniform insertion loss. The insertion loss difference of all 36 channels is controlled within a very small range. The ferrule body, as a high-precision reference platform, aligns and fixes multiple fibers through its internal micro-hole array. Through the cooperation of the guide holes at both ends of the ferrule and the external guide pins (PINs), submicron-level precision docking with the docking port on the CPO optical engine is achieved, ensuring the signal integrity of the high-speed parallel optical link and meeting the consistency and stability requirements of optical coupling for 1.6T and above CPO systems.

[0069] A mold for a method of manufacturing a ferrule suitable for CPO technology, as described in the preferred embodiment of the third aspect of this application, such as... Figure 4 As shown, the system includes a moving mold 50 and a corresponding fixed mold 51. The fixed mold has 36 sets of parallel V-shaped positioning grooves, and mold pins 52 can be placed in the V-shaped positioning grooves. Guide grooves 54 are provided on both sides of the V-shaped positioning grooves, and guide pins 56 can be placed in the guide grooves. The moving mold and the fixed mold also have cavities 55 that communicate with the V-shaped positioning grooves. The parameters of each set of V-shaped grooves are as follows: the groove spacing is 127.0±0.1μm, the V-angle of the V-shaped groove is 90°±0.5′, the groove depth is 150μm, and the cumulative spacing error of all V-shaped grooves must be controlled within ±0.2μm. Furthermore, the cavity is a one-piece molded flat structure with a long, flat strip shape. Its dimensions meet the requirements of a thickness of 1.25 mm and a width of 7 mm. The mold needle is made of tungsten steel with a diameter of 80.0 ± 0.1 μm and a straightness error of less than 1 μm / 50 mm. The ferrule with 36 fiber optic holes is manufactured using the above manufacturing method. Due to the line contact method of the V-shaped positioning groove, compared with the traditional point contact or small plane contact, it can more effectively restrict the displacement of the mold needle in multiple degrees of freedom, ensuring that the parallelism and relative position of all mold needles do not drift during the injection molding process, thereby guaranteeing the final position accuracy of the ferrule hole.

[0070] It should be understood that this application has been described through some embodiments, and those skilled in the art will recognize that various changes or equivalent substitutions can be made to these features and embodiments without departing from the spirit and scope of this application. Furthermore, based on the teachings of this application, these features and embodiments can be modified to suit specific circumstances and materials without departing from the spirit and scope of this application. Therefore, this application is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are within the protection scope of this application.

Claims

1. A method for manufacturing a ferrule suitable for CPO technology, characterized in that, Includes the following steps: Prepare a mold with multiple mold pin positioning grooves, wherein the multiple mold pin positioning grooves are arranged in a single row and are set in parallel; Place the die needles in each set of die needle positioning slots so that they contact the positioning slot line and form a die needle array; The moving mold and the fixed mold are closed to form the mold body by injection molding; After the core body cools and solidifies, it is cleaned and annealed, and then demolded to obtain the formed core. Inspect the fiber optic hole accuracy of the shaped ferrule.

2. The manufacturing method according to claim 1, characterized in that: The process of closing the mold by fitting the moving mold and the fixed mold together and then performing injection molding to form the insert body also includes: The array material is dried to reduce its water content to a preset value and then heated to obtain the injection molding melt; Under a first pressure value, at a first speed, molten plastic is injected into the mold to the first preset condition; Once the first preset condition is met, the injection melt is injected at the second speed until the second preset condition is met. Once the second preset condition is met, the speed is switched to the third speed and adjusted to the second pressure value. The pressure is maintained at the second pressure value for a preset time to complete the injection molding and obtain the ferrule body.

3. The manufacturing method according to claim 2, characterized in that: The first preset condition is that the injection melt is adjusted from the first speed to the second speed after it passes around the mold tip; The second preset condition is that the percentage of the injection melt filling the cavity reaches a preset value.

4. The manufacturing method according to claim 2, characterized in that: The first speed and the third speed are less than the second speed, and the first pressure value is less than the second pressure value.

5. The manufacturing method according to claim 1, characterized in that: The process of cleaning and annealing after the core body is cooled and formed, and then demolding to obtain the formed core, also includes: Before the core body is demolded, the temperature difference between the moving mold and the fixed mold is controlled within a threshold range, and demolding is only performed when the temperature difference between the moving mold and the fixed mold is less than the threshold.

6. The manufacturing method according to claim 1, characterized in that: The positioning groove of the mold needle is a V-shaped positioning groove or a precision hole. The groove spacing of the V-shaped positioning groove is 127.0±0.1μm, the V-angle of the V-shaped positioning groove is 90°±0.5′, the groove depth of the V-shaped positioning groove is 150μm, the cumulative spacing error of all the V-shaped positioning grooves is less than ±0.2μm, the diameter of the mold needle is 80.0±0.1μm, and the diameter of the precision hole is 80+0.50μm.

7. A ferrule suitable for CPO technology, characterized in that: The ferrule is manufactured using a method for manufacturing a ferrule suitable for CPO technology as described in any one of claims 1 to 6. The ferrule includes a ferrule body and a plurality of fiber optic holes disposed on the ferrule body, wherein the plurality of fiber optic holes are arranged in a single row in parallel.

8. The ferrule according to claim 7, characterized in that: The fiber optic hole is provided with guide holes on both sides. There are a total of 36 groups of fiber optic holes. Each group of fiber optic holes is the same size and has a diameter of 80 ± 0.50 μm. The cumulative center error of the 36 groups of fiber optic holes is less than ± 0.7 μm. The ferrule body has a thickness of 1.25 mm and a width of 7 mm.

9. A mold, characterized in that: A method for manufacturing a ferrule suitable for CPO technology as described in any one of claims 1 to 6, wherein the mold includes a moving mold and a fixed mold corresponding to the moving mold, both the moving mold and the fixed mold being provided with cavities, and the fixed mold being provided with multiple sets of parallel positioning grooves, wherein mold pins can be placed in the positioning grooves.

10. The mold according to claim 9, characterized in that: The positioning groove is a V-shaped positioning groove, which is arranged in a single row in parallel. The groove spacing of the V-shaped positioning groove is 127.0±0.1μm, the V-angle of the V-shaped positioning groove is 90°±0.5′, the groove depth of the V-shaped positioning groove is 150μm, and the cumulative spacing error of all the V-shaped positioning grooves is less than ±0.2μm.

Images