Optical Connector Ferrule Mold Pin Width Compensation
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Solution Overview
Problem
The existing mold-based production of optical connector ferrules often results in inclined fiber holes due to resin shrinkage, leading to misalignment and shifting of fiber holes during the polishing process.
Innovation Solution
The optical connector ferrule design features a specific arrangement of fiber holes with varying diameters and grooves, and a mold with pin rows of different average widths to minimize resin flow-induced inclination, using a multi-part mold with guide and fiber hole pins to maintain alignment during resin solidification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a mold with pins is used to produce optical connector ferrule, then the ferrule can be formed with multiple fiber holes, but resin shrinkage causes the pins to incline and fiber holes to become misaligned
Solution Approach 1:
The mold is divided into multiple independent pin rows (first pin row and second pin row) with different average widths, allowing each row to be optimized independently for its specific position and resin flow conditions
Solution Approach 2:
Different pin rows are given different average widths based on their local requirements - the first pin row has a smaller average width while the second pin row has a larger average width, creating local variations in mold structure to compensate for resin shrinkage at different positions
2Productivity
If resin is injected into the mold and solidified, then the ferrule structure is formed, but resin shrinkage causes pins to incline during solidification
Solution Approach 1:
The mold pins are designed with different average widths in advance to preemptively counteract the resin shrinkage forces that will occur during solidification, preventing pin inclination before it happens
Solution Approach 2:
The first and second pin rows are designed with asymmetric average widths, creating an intentional imbalance in the mold structure that compensates for the symmetric resin shrinkage forces acting on the ferrule
3Shape
If fiber holes are inclined before polishing, then the end surface can be polished at an angle, but the opening positions of fiber holes shift on the end surface
Solution Approach 1:
The mold pin design preemptively establishes the correct fiber hole positions and orientations before the polishing process, ensuring that even after angled polishing, the fiber holes maintain their intended alignment and opening positions
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 design effectively reduces the inclination of fiber holes by balancing the resin flow forces, ensuring accurate positioning and alignment of fiber holes, thereby improving the precision and reliability of the optical connector ferrule.
Implementation Method 1
in a step of solidifying a resin, the resin shrinks and thus the pins are sometimes inclined
Data Source
AI summary
An optical connector ferrule having a front end, a rear end, an upper surface, and a lower surface includes a window opening on the upper surface, a plurality of fiber holes passing through a portion between the front end and the window along a first direction and including small diameter portions on the front end side and large diameter portions on the window side, and fiber grooves extending from the large diameter portions along the first direction and having openings in a third direction, in which the plurality of fiber holes include a first fiber hole row arranged in a second direction on a lower surface side, and a second fiber hole row arranged in the second direction on the upper surface side, and the large diameter portion in the second fiber hole row is longer than the large diameter portion in the first fiber hole row.