Angle Polishing Multi-Ferrule Connectors via Coplanar Adjustment
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Solution Overview
Problem
The challenge lies in implementing lateral angle polishing for tandem ferrule connectors, such as the SEN type, to achieve reliable and cost-effective angle-polished connectors (APCs) with consistent end-face geometry.
Innovation Solution
The solution involves positioning the ferrule end faces in a substantially coplanar orientation during polishing, using mechanisms like split connector bodies, compression springs, and polishing fixtures with slide cams or sleeving elements to adjust the vertical offset and facilitate lateral polish orientation in the mating position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If standard connectors are inserted at the requisite angle for APC polishing, then the angle polish can be applied, but the ferrule end faces will not be coplanar (one ferrule will stand roughly 0.5 mm lower than the other)
Solution Approach 1:
The polishing fixture incorporates movable ferrule holders that can independently adjust the vertical position of each ferrule. This dynamic adjustment capability allows the system to compensate for the inherent non-coplanar geometry of tandem ferrule connectors during polishing, ensuring both ferrules can be positioned coplanarly on the polishing surface while maintaining their angled insertion configuration.
Solution Approach 2:
The polishing fixture acts as an intermediary device between the non-coplanar ferrule arrangement and the polishing process. It introduces intermediate adjustment mechanisms (movable holders, positioning elements) that temporarily modify the ferrule positions during polishing, enabling coplanar alignment without altering the permanent connector geometry.
2Manufacturing precision
If ferrules are polished individually prior to assembly, then consistent end-face geometry can be achieved, but the connector assembly process becomes divided between extensive pre-polish and post-polish assembly operations
Solution Approach 1:
The system merges the polishing operation with the assembled connector by providing a fixture that can hold and polish multiple ferrules in their final assembled configuration. This eliminates the need to separate polishing and assembly operations, allowing ferrules to be polished together as a unit while maintaining their relative positions and orientations.
Solution Approach 2:
The ferrules are pre-assembled into the connector housing with their final positioning elements in place before polishing. This preliminary assembly ensures that the polishing process operates on the ferrules in their exact final positions, eliminating the need for post-polish repositioning or additional assembly steps.
3Manufacturing precision
If vertical orientation conventions are used for multi-fiber MPO connector types, then angle polishing can be applied, but either an inversion of the mating connector or employment of two different angled connector types is required
Solution Approach 1:
The system employs asymmetric positioning elements and ferrule holders that are specifically configured for tandem ferrule arrangements. The fixture design incorporates asymmetric support structures, positioning pins, and clamping mechanisms that accommodate the unique side-by-side geometry of SEN-type connectors, enabling proper angle polishing without requiring connector inversion or multiple connector types.
Data Source
AI summary
Systems and methods for angle polishing of the end faces of a plurality of optical connectors are provided. Systems are provided that include a connector defining a longitudinal axis, and at least two ferrules mounted with respect to the connector and arranged in a side-by-side orientation. The end faces of the connectors are movable relative to the connector and such movement facilitates lateral orientation of the angle polished end faces of the ferrules relative to the connector when in the mating position. Various mechanisms and methods for facilitating movement of the ferrules relative to the connector are disclosed to achieve the desired lateral polish orientation of the ferrule end faces.