Ferrule Assembly Lateral Injection Hole Design
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Solution Overview
Problem
In the manufacturing of fiber optic connectors, inserting a fiber into a ferrule assembly before filling adhesive can result in damage due to the adhesive injection needle touching the fiber, and the adhesive often adheres to the fiber, increasing insertion resistance and degrading optical performance.
Innovation Solution
A ferrule assembly design with an additional injection hole on its external surface, allowing adhesive to be injected directly into the fiber bore without entering the fiber, preventing damage and ensuring the fiber remains clean.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive is injected through the axial rear port into the hollow chamber, then the adhesive can be filled into the ferrule assembly, but the adhesive injection needle may touch and damage the fiber that has been inserted into the ferrule assembly
Solution Approach 1:
The patent divides the adhesive injection path into two separate access points: the original axial rear port for general adhesive filling, and a new laterally positioned injection hole for precise adhesive delivery. This segmentation allows the injection needle to access the fiber bore without traversing the entire length of the hollow chamber, thereby avoiding contact with the inserted fiber while still achieving complete adhesive coverage.
Solution Approach 2:
The injection hole acts as an intermediary access point that mediates between the adhesive injection needle and the fiber bore. By providing a direct lateral pathway into the fiber bore region, it enables adhesive delivery without requiring the needle to pass through the hollow chamber where the fiber resides, thus protecting the fiber from mechanical damage.
2Reliability
If the adhesive injection needle depth is reduced to avoid touching the fiber, then the fiber is protected from damage, but the adhesive cannot reach the hollow chamber and cannot flow over the whole fiber bore
Solution Approach 1:
The patent creates a dual-access system where the injection hole provides direct access to the fiber bore region, enabling the adhesive to be deposited precisely where needed without requiring deep insertion through the hollow chamber. This segmented access strategy simultaneously achieves fiber protection and complete adhesive coverage of the fiber bore.
Solution Approach 2:
The injection hole introduces a lateral (horizontal) dimension to the adhesive injection process, contrasting with the original axial (vertical) injection path through the hollow chamber. This dimensional change allows the needle to reach the fiber bore from the side, avoiding the need for deep axial insertion that would risk fiber contact while still ensuring complete adhesive distribution.
3Manufacturing precision
If adhesive is filled into the hollow chamber before fiber insertion, then the adhesive can be properly positioned, but the adhesive adheres to the fiber increasing insertion resistance and may cause fiber breakage
Solution Approach 1:
The injection hole enables preliminary adhesive deposition directly into the fiber bore region before fiber insertion. By allowing adhesive to be positioned in advance through this lateral access point, the system prepares the bonding interface without filling the entire hollow chamber, thus preventing adhesive from coating the fiber during subsequent insertion and eliminating insertion resistance issues.
Solution Approach 2:
The patent extracts the adhesive deposition function from the general hollow chamber filling process and creates a dedicated injection hole specifically for precise adhesive delivery into the fiber bore. This extraction allows adhesive to be positioned exactly where needed without unnecessarily filling the hollow chamber, thereby preventing adhesive-fiber contact during insertion while maintaining proper adhesive positioning.
Data Source
AI summary
A ferrule assembly including: a ferrule formed with a fiber bore for receiving an optical fiber therein; and a rear seat connected to a rear end of the ferrule, wherein the rear seat is formed with a hollow chamber passing through the rear seat in a longitudinal direction and communicated with the fiber bore of the ferrule, and wherein an additional injection hole for injecting an adhesive into the ferrule assembly is formed in an external profile surface of the ferrule assembly, and directly communicated with the fiber bore of the ferrule or the hollow chamber of the rear seat. The ferrule assembly is configured to be adapted to insert a fiber before filling an adhesive and protect the fiber that has been inserted into the ferrule assembly during inserting the fiber or filling the adhesive into the ferrule assembly.