Optical Connector Ferrule Mold Pin Alignment

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Solution Overview

Problem

Existing methods for manufacturing optical connector ferrules face challenges in accurately aligning optical fiber holding holes, leading to misalignment issues due to identical lengths of small diameter portions in mold pins, resulting in curved positions of these holes on the end surface.

Innovation Solution

The method involves using mold pins with varying lengths of small diameter portions, allowing for adjustments in the positions of optical fiber holding holes by differentiating the lengths of these portions, and positioning the gate away from the end surface to enhance alignment accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If mold pins with identical lengths of small diameter portions are used, then the manufacturing process is simple, but the optical fiber holding holes become misaligned and curved on the end surface

Engineering Contradiction:

Improvemold pin configuration simplicityVSAvoidoptical fiber holding hole alignment accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies local quality by making each mold pin have a different length of small diameter portion according to its specific position in the array. This localized variation in pin configuration allows each optical fiber holding hole to be precisely positioned at its required location, eliminating the curvature and misalignment that occurs when all pins have identical lengths. The local adjustment of pin lengths directly addresses the alignment precision issue without requiring complete redesign of the entire mold system.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the parameter of mold pin length (specifically the length of the small diameter portion) to control the position of optical fiber holding holes. By varying this dimensional parameter across different pins, the invention achieves precise alignment of holes on the end surface. This parameter change approach transforms the fixed, uniform pin configuration into a variable configuration that can be optimized for each position, resolving the alignment accuracy problem.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If the gate is positioned close to the end surface, then the resin fills the cavity quickly, but the optical fiber holding holes become misaligned

Engineering Contradiction:

Improveresin filling speedVSAvoidoptical fiber holding hole alignment accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by positioning the gate away from the end surface where the optical fiber holding holes are located. This preliminary positioning decision prevents resin flow from directly affecting the hole alignment area during the filling process. By establishing the gate position in advance to be distant from the critical alignment zone, the invention ensures that resin filling occurs without disrupting the precise positioning of optical fiber holding holes, thus maintaining alignment accuracy while still achieving efficient cavity filling.

Inventive Principle:

Principle #10Preliminary action

3Device complexity

If all mold pins have the same small diameter portion length, then the mold structure is uniform and simple, but the optical fiber holding holes form a curved pattern instead of being properly aligned

Engineering Contradiction:

Improvemold pin structure uniformityVSAvoidoptical fiber holding hole position accuracy

Core Design Contradiction:

Device complexityVSShape

Solution Approach 1:

The patent applies asymmetry by intentionally making the small diameter portion lengths of different mold pins unequal. This asymmetric configuration is designed to compensate for the natural curvature that occurs during resin filling and to achieve proper alignment of optical fiber holding holes. By introducing controlled asymmetry in pin lengths, the invention transforms the uniform but flawed symmetric arrangement into an optimized asymmetric arrangement that produces straight, properly aligned holes on the end surface.

Inventive Principle:

Principle #4Asymmetry

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

This approach enables precise adjustment and alignment of optical fiber holding holes, reducing misalignment and curvature issues, thereby improving the manufacturing process for optical connector ferrules.

Implementation Method 1

introducing resin into a cavity of a mold, the cavity taking a shape of the optical connector ferrule, and hardening the resin to form the optical connector ferrule

Methodology Applied

Scientific EffectHardening: Phase Change

Data Source

PatentUS11340407B2Method for manufacturing optical connector ferrule and optical connector ferrule

Publication Date: 2022.05.24 SUMITOMO ELECTRIC INDUSTRIES LTD

AI summary

Optical fiber hole forming pins configured to form optical fiber holding holes each have a first portion located adjacent to a first end surface and a second portion located adjacent to a second end surface and larger in diameter than the first portion. At least one of the plurality of optical fiber hole forming pins is different from the other optical fiber hole forming pins in position, in a first direction, of a step portion located at a boundary between the first portion configured to form a small diameter portion of each of the optical fiber holding holes and the second portion configured to form a large diameter portion of each of the optical fiber holding holes.