Expanded Beam Connector Bore Channels for Air Escape

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Solution Overview

Problem

Manufacturing expanded beam connectors to precise micrometre tolerances is challenging due to difficulties in air escape and frictional forces during fibre optic ferrule insertion, making the process costly and time-consuming.

Innovation Solution

Incorporating a plurality of channels with a constant cross-sectional shape or area in the bore perimeter to allow air escape and reduce frictional forces, along with a lens positioned adjacent to the open end of the bore, facilitates easier insertion and manufacturing of expanded beam connectors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If tight micrometre tolerances are specified for the bore to ensure precise fibre optic ferrule positioning, then optical performance criteria are met, but manufacturing difficulty and cost increase significantly

Engineering Contradiction:

Improvebore toleranceVSAvoidmanufacturing difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The bore surface is segmented by introducing circumferential channels that divide the continuous cylindrical surface into distinct sections. This segmentation allows air to escape through multiple pathways during ferrule insertion, reducing the difficulty of achieving tight tolerances while maintaining precise positioning capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The channels act as an intermediary mechanism between the bore and the external environment, providing a controlled pathway for air evacuation. This intermediary structure facilitates easier insertion of the ferrule while preserving the tight dimensional tolerances required for optical performance.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If tight micrometre tolerances are specified for the bore to ensure precise fibre optic ferrule positioning, then optical performance criteria are met, but insertion difficulty increases due to trapped air and friction

Engineering Contradiction:

Improvebore toleranceVSAvoidinsertion difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The bore surface is segmented by introducing circumferential channels that divide the continuous cylindrical surface into distinct sections. This segmentation allows air to escape through multiple pathways during ferrule insertion, reducing insertion difficulty while maintaining precise positioning capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The channels convert the harmful effect of trapped air (which causes insertion difficulty) into a beneficial feature by providing controlled evacuation pathways. The same structural elements that define the bore geometry also facilitate air escape, turning a potential problem into a solution.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of manufacture

If traditional smooth bore design is used, then manufacturing is easier, but air becomes trapped during ferrule insertion causing insertion difficulty

Engineering Contradiction:

Improvemanufacturing easeVSAvoidinsertion difficulty

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The bore is designed with a porous-like structure through the addition of circumferential channels. This creates multiple small pathways for air to escape, similar to how porous materials allow fluid passage, while maintaining the overall structural integrity and dimensional stability of the bore.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The solution moves from a two-dimensional smooth cylindrical surface to a three-dimensional structured surface with circumferential channels. This dimensional change adds depth and complexity to the bore geometry, creating air escape pathways without compromising manufacturing feasibility.

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 solution simplifies the insertion process by allowing trapped air to escape and reducing frictional forces, thereby lowering manufacturing costs and time while maintaining the required tight tolerances.

Implementation Method 1

the channels are positioned to allow the passage of air out of the bore as a fibre optic ferrule is inserted into the bore

Methodology Applied

Scientific EffectAir escape through channels:

Implementation Method 2

this precision lens used to increase the diameter of the beam transported along the fibre optic fibre by several orders of magnitude

Methodology Applied

Scientific EffectBeam expansion through lens: Lens

Implementation Method 3

a second lens in a second expanded beam connector collects the light from the first lens and focuses it into a second fibre optic fibre

Methodology Applied

Scientific EffectLight focusing through lens: Lens

Data Source

PatentEP3612879B1Expanded beam connector

Publication Date: 2022.11.16 RIDGEMOUNT TECHNOLOGIES LTD

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AI summary

An expanded beam connector for use with a fibre optic fibre is described, the expanded beam connector comprising; a body and at least one bore located within said body for accepting a fibre optic ferrule, wherein the perimeter of said bore comprises at least one channel extending from an open end of said bore. Methods of manufacturing an expanded beam connector are also described.