Fiber Optic Ferrule Complementary Mating Geometry Wear Reduction

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Solution Overview

Problem

Conventional fiber optic connectors are not suitable for consumer electronic devices due to their large size, sensitivity to environmental debris, and limited number of mating cycles, which are often required in consumer devices operating in various environments with size and space constraints.

Innovation Solution

The development of optical fiber ferrules with complimentary mating geometry, featuring a slot for reduced wear and debris, and a second ferrule with monolithically formed guide pins and spring retention features, allowing for a high number of mating cycles and quick assembly, suitable for consumer electronic devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of moving object

If conventional fiber optic connectors are used, then optical connectivity is achieved, but the number of mating cycles is limited and wear debris is generated

Engineering Contradiction:

Improvenumber of mating cyclesVSAvoidwear debris

Core Design Contradiction:

Duration of action of moving objectVSObject-generated harmful factors

Solution Approach 1:

The connector is divided into two separate ferrules (first ferrule and second ferrule) with complementary mating geometry. The first ferrule has a slot while the second ferrule has a guide pin, creating a segmented mating system where each component has a specific function. This segmentation allows the slot and guide pin to mate without direct metal-to-metal contact that generates wear debris, thereby enabling a high number of mating cycles.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The slot-guide pin interface acts as an intermediary mechanism between the two ferrules. Instead of direct contact between similar features, the slot in the first ferrule receives and guides the guide pin in the second ferrule, creating a controlled mating interface that reduces wear and debris generation while enabling repeated mating cycles.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If conventional fiber optic connectors are used, then optical connectivity is achieved, but the connector size is large and not suitable for consumer devices

Engineering Contradiction:

Improveconnector sizeVSAvoidsuitability for consumer devices

Core Design Contradiction:

Volume of moving objectVSAdaptability or versatility

Solution Approach 1:

Multiple features are merged into single components to reduce overall connector size. The first ferrule integrates the slot feature directly into its body, and the second ferrule integrates the guide pin and spring retention feature into a single monolithic structure. This merging eliminates the need for separate alignment features and reduces the overall connector volume, making it suitable for consumer electronic devices with space constraints.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If conventional fiber optic connectors are used, then optical connectivity is achieved, but cleaning and careful deployment are required

Engineering Contradiction:

Improvedeployment simplicityVSAvoidenvironmental debris sensitivity

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The slot-guide pin mating geometry converts the potential harm of environmental debris into a beneficial self-cleaning mechanism. The slot in the first ferrule and the guide pin in the second ferrule are designed such that the guide pin fits within the slot tolerance, allowing the mating process itself to wipe or clean the interfaces. This design enables deployment in environments with dust and debris without requiring pre-cleaning, as the mating action naturally removes contaminants.

Inventive Principle:

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

4Ease of manufacture

If the second ferrule includes monolithically formed guide pins and spring retention features, then the number of parts is reduced and assembly is quick, but manufacturing precision is required

Engineering Contradiction:

Improveassembly speedVSAvoidmating geometry precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The guide pin and spring retention feature are merged into a single monolithic second ferrule component. This integration reduces the total number of parts from multiple separate components to a single ferrule body, significantly simplifying assembly and reducing the number of assembly steps. The monolithic structure eliminates the need for separate assembly of guide pins and retention features, enabling quick assembly while maintaining precise mating geometry through single-piece manufacturing.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS10401572B2Fiber optic connectors including ferrules with complementary mating geometry and related fiber optic connectors

Publication Date: 2019.09.03 CORNING OPTICAL COMMUNICATIONS LLC

AI summary

Optical fiber ferrules with complementary mating geometry that are suitable for making optical connections are disclosed along with fiber optic connectors and cable assemblies using the same. In one embodiment, the fiber optic ferrule includes a body having a plurality of optical pathways and a mating geometry that has at least one guide pin that is monolithically formed in the body of the fiber optic ferrule and at least one spring retention feature disposed on a rear portion of the ferrule. The ferrule reduces the number of parts required for a fiber optic connector and allows quick and easy assembly. The disclosure is also directed to fiber optic connectors and cable assemblies using the ferrule.