Ferrule Forming Method Correcting Optical Fiber Core Offset
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Solution Overview
Problem
Optical fiber connectors face significant insertion loss due to core-to-ferrule concentricity errors, which arise from misalignment of the optical fiber cores and ferrule centers, leading to inefficient optical coupling.
Innovation Solution
A method of forming a ferrule with an inner member and an outer member, where the outer member is designed to correct the concentricity error by positioning the optical fiber core closer to the ferrule geometric center, reducing the offset distance from the ferrule geometric center compared to the inner member, thereby improving the core-to-ferrule concentricity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a traditional ferrule with a single outer surface is used, then the manufacturing process is simple, but the core-to-ferrule concentricity error is high
Solution Approach 1:
The ferrule is divided into two distinct members: an inner member that provides the axial bore for fiber insertion and an outer member that defines the final outer surface. This segmentation allows independent optimization of each component's function, enabling high concentricity precision without excessive overall complexity.
Solution Approach 2:
The inner member is formed first with its axial bore, then the outer member is formed over it. This preliminary action allows the concentricity relationship between the fiber core and ferrule center to be established and corrected during the sequential formation process, achieving high precision through controlled manufacturing stages.
2Reliability
If the ferrule is formed as a single piece, then the manufacturing process is straightforward, but the coupling efficiency is reduced due to concentricity errors
Solution Approach 1:
By segmenting the ferrule into inner and outer members formed in sequence, the patent achieves superior concentricity and coupling efficiency. The two-stage formation process allows precise control of the fiber core alignment with the ferrule center, directly improving reliability while the modular approach maintains manufacturing feasibility.
Solution Approach 2:
The sequential formation process incorporates feedback control where the position of the fiber core relative to the inner member is measured, and the outer member is subsequently formed to correct any concentricity deviations, ensuring optimal coupling efficiency.
3Loss of energy
If the inner member geometric center is used as the ferrule center, then the manufacturing alignment is simple, but the insertion loss is high due to core misalignment
Solution Approach 1:
The outer member acts as an intermediary that mediates between the inner member's geometric center and the desired ferrule center. By forming the outer member with a specifically positioned outer surface, the patent creates a new reference center that aligns with the fiber core, minimizing insertion loss while maintaining manufacturing precision.
Solution Approach 2:
The inner member is formed first with its bore, then the outer member is formed over it with the fiber core already in position. This preliminary action allows the final ferrule center to be established based on the actual fiber core position rather than the inner member's geometric center, reducing concentricity error and insertion loss.
Data Source
AI summary
Methods of forming a ferrule are disclosed where the ferrule includes an inner member and an outer member. An optical fiber is secured in an axial bore of the inner member, and then offset of a core of the optical fiber from a geometric center of the inner member is determined. The outer member is then formed over the inner member to “correct” for this offset so that the core of the optical fiber ends up closer to the geometric center of the resulting ferrule. Related ferrules and cable assemblies including the same are also disclosed.