Fusion Splice Connector Holder for Stable Low-Loss Fiber Alignment
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Solution Overview
Problem
Existing mechanical splice-on connectors for fiber optic connections suffer from higher insertion loss due to the mismatch in optical properties between glass and index matching gel, while fusion splice connectors are not preferred due to the high cost of fusion splice equipment.
Innovation Solution
A fusion splice connector system with a fiber optic fiber and a connector holder that encloses the cable-to-cable splice within a housing, featuring a connector base with support pads and ribs to stabilize the ferrule holder, and a protective sleeve for fusion splicing using common industry equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical splice-on connectors with index matching gel are used, then ease of termination and cost of equipment are improved, but insertion loss increases due to optical property mismatch between glass and gel
Solution Approach 1:
The patent removes the index matching gel from the connector design entirely, extracting the problematic element that caused optical property mismatch. The ferrule is designed to hold fibers in direct contact without any gel medium, eliminating the source of insertion loss while maintaining the mechanical ease of termination through the cam action buffer clamp.
Solution Approach 2:
The patent achieves optical homogeneity by eliminating the gel layer that created optical property differences between the glass fiber and coupling medium. The direct glass-to-glass contact through the ferrule creates a homogeneous optical path, ensuring consistent refractive index throughout the connection and minimizing insertion loss.
2Loss of energy
If fusion splice connectors are used, then insertion loss is reduced through thermal fusion of glass, but cost of equipment increases due to expensive fusion splice equipment
Solution Approach 1:
The patent divides the fusion splice connector into separable components: a factory-polished ferrule with stub fiber and a field-terminated connector body. This segmentation allows the precision ferrule to be manufactured under controlled conditions while the field connector uses simpler, less expensive components, reducing overall equipment cost while maintaining low insertion loss through precise ferrule alignment.
Solution Approach 2:
The patent performs the critical precision work in advance by factory-polishing the ferrule and pre-positioning the stub fiber. This preliminary action ensures accurate alignment and low insertion loss without requiring expensive fusion splice equipment at the field termination site, as the alignment is already established during manufacturing.
3Ease of manufacture
If fusion splice equipment cost is reduced for field use, then ease of manufacture is improved, but reliability may worsen due to potential misalignment or movement
Solution Approach 1:
The patent provides beforehand cushioning for alignment stability through the precision-engineered ferrule design with buffer clamp and retaining features. These elements are pre-configured to maintain precise fiber alignment and prevent movement, ensuring reliable connections even with simplified, cost-effective field termination equipment.
Solution Approach 2:
The patent replaces complex fusion splice mechanical systems with a simpler mechanical splice-on connector system that uses a cam action buffer clamp and ferrule-based alignment. This substitution maintains reliability through precise mechanical positioning while reducing equipment cost and complexity for field use.
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 system provides a low-loss fiber optic connection by fusing glass fibers, reducing insertion loss and maintaining alignment stability, while utilizing cost-effective fusion splicing machines.
Implementation Method 1
a fusion splice type splice-on connector where glass is fused thermally to offer lowest loss connector
Data Source
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AI summary
A system for connecting a fusion splice connector to an optical fiber has a fiber optic fiber, a fusion splice connector wherein a cable-to-cable splice is fully enclosed within a connector housing, and a connector holder. The connector holder has a connector base with a front support pad configured to provide support to a first portion of the ferrule holder and a rear support rib configured to provide support to the ferrule holder at a point distal from the first portion.