Fiber Optic Connector Ferrule Bore Segmentation
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Solution Overview
Problem
Current fiber optic connector sub-assemblies face challenges in securely positioning and retaining bonding agents within ferrule bores, leading to potential migration and inconsistent termination processes during fiber optic cable assembly.
Innovation Solution
A fiber optic connector sub-assembly design that includes a ferrule with a specific bore structure and a bonding agent distribution method, where the bonding agent is initially disposed in the ferrule bore and heated to melt and solidify at specific ends, forming a crust portion that securely couples to the ferrule, while maintaining a powder portion in the middle, ensuring stability and adhesion during cable assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the bonding agent is disposed in the ferrule bore, then the bonding agent can be pre-loaded for future connectorization, but the bonding agent may migrate during storage and handling
Solution Approach 1:
The bonding agent is segmented into two distinct portions: a crust portion formed at the ends of the ferrule bore and a powder portion remaining in the middle section. This segmentation allows the crust portion to provide anchoring stability preventing migration, while the powder portion maintains its flowability for proper fiber embedding during connectorization.
Solution Approach 2:
Different portions of the bonding agent are given different physical states and properties: the crust portion at the ends is solidified to provide stability and prevent migration, while the powder portion in the middle remains in powder form to maintain adhesion properties and flowability for fiber embedding. This local differentiation resolves the contradiction between stability and adhesion.
2Stability of the object's composition
If the bonding agent is heated to melt and solidify, then the bonding agent forms a crust portion that reduces migration, but the bonding agent may lose its adhesion properties
Solution Approach 1:
The bonding agent is heated only at the ends of the ferrule bore to form crust portions, while the middle section remains unheated and retains its powder state. This selective heating segments the bonding agent into stable crust portions for migration prevention and adhesive powder portions for fiber bonding, resolving the contradiction between stability and adhesion strength.
Solution Approach 2:
The heating process is applied locally only to the end regions of the ferrule bore, creating crust portions with different properties than the central powder portion. The crust portions provide positional stability, while the unheated powder portion maintains its adhesion properties, thus resolving the contradiction between stability and bonding strength.
3Stability of the object's composition
If the bonding agent is fully solidified, then migration is prevented, but the bonding agent cannot properly embed the optical fiber during termination
Solution Approach 1:
The bonding agent is segmented into crust portions at the ends that are solidified for migration prevention, and a powder portion in the middle that remains unfrozen to enable fiber embedding during termination. This segmentation allows both stability and ease of operation to be achieved simultaneously.
Solution Approach 2:
Different regions of the bonding agent have different physical states: the end regions are solidified to prevent migration, while the central region remains in powder form to provide the necessary flowability and adhesion for proper fiber embedding during the termination process, resolving the contradiction between stability and operational ease.
4Strength
If more bonding agent is placed in the ferrule bore, then adhesion coverage is improved, but the bonding agent is more prone to migration during storage
Solution Approach 1:
The bonding agent is segmented into crust portions at the ends that anchor the bonding agent in place, preventing migration even when large amounts are present. The powder portion in the middle provides extensive adhesion coverage without migrating, as the crust portions act as anchors. This segmentation allows both improved adhesion coverage and position stability.
Solution Approach 2:
The bonding agent is given different properties at different locations: solidified crust portions at the ends provide stability and prevent migration, while the powder portion in the middle provides extensive adhesion coverage. This local differentiation allows large amounts of bonding agent to be used for improved coverage without increasing migration risk.
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 enhances the secure coupling of the bonding agent to the ferrule, reducing migration and improving the consistency of the termination process, while preserving the bonding agent's ability to form strong adhesion properties at the time of cable assembly, even after extended storage or handling.
Implementation Method 1
heating at least a portion of the ferrule above a melting temperature of the bonding agent initially disposed in the ferrule bore so that some of the bonding agent melts
Implementation Method 2
solidifying the bonding agent that has melted in step (b) to form the fiber optic connector sub-assembly
Data Source
AI summary
A fiber optic connector sub-assembly includes a ferrule having a front end, a rear end, and a ferrule bore extending between the front and rear ends along a longitudinal axis. The ferrule bore has a first section extending inwardly from the rear end of the ferrule, a second section extending inwardly from the front end of the ferrule and having a width that is less than the first section, and a transition section located between the first and second sections. The fiber optic connector sub-assembly also includes a bonding agent disposed in at least a portion of both the transition section and the second section of the ferrule bore. At least some of the bonding agent in the second section of the ferrule bore has been melted and solidified.