Ferrule with Embedded Reinforcement Member for Fiber Alignment
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Solution Overview
Problem
Existing ferrule designs with resin-molded fiber holes suffer from positional misalignment due to temperature changes, as the resin's high linear expansion coefficient causes contraction and expansion issues, making it difficult to maintain accurate fiber hole positioning.
Innovation Solution
A ferrule design incorporating a resin-molded portion with a reinforcement member having a smaller linear expansion coefficient, where the fiber holes are formed by resin entering into fiber insertion portions within the reinforcement member, which are either through holes or grooves, to improve positional accuracy and prevent deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fiber holes are formed by resin molding inside a rectangular-tubular reinforcement member, then the linear expansion coefficient of the resin is large causing positional misalignment among fiber holes due to temperature changes, but forming fiber holes directly in the reinforcement member is difficult to achieve with high positional and dimensional accuracy
Solution Approach 1:
The invention divides the fiber hole formation process into two segments: (1) forming fiber insertion portions (grooves or holes) in the reinforcement member with low linear expansion coefficient, and (2) injecting resin into these portions to form the actual fiber holes. This segmentation allows each component to contribute its advantageous properties - the reinforcement member provides dimensional stability and positional accuracy, while the resin provides ease of molding and filling.
Solution Approach 2:
The resin is nested inside the fiber insertion portions of the reinforcement member. The fiber insertion portions act as molds or cavities within the reinforcement member, and the resin is injected into these nested spaces to form the fiber holes. This nested structure ensures that the fiber holes inherit the positional accuracy of the reinforcement member while being formed through resin injection.
2Stability of the object's composition
If a reinforcement member with small linear expansion coefficient is used, then contraction of the ferrule is prevented, but positional misalignment among fiber holes occurs due to expansion/contraction of the resin inside the reinforcement member
Solution Approach 1:
The invention applies local quality by creating fiber insertion portions (grooves or holes) with specific geometric characteristics within the reinforcement member. These localized structures serve as precise templates for fiber hole formation, ensuring that the critical regions (where fibers will be inserted) maintain high positional accuracy regardless of overall resin expansion or contraction.
Solution Approach 2:
The invention creates a composite structure combining the reinforcement member (with low linear expansion coefficient for dimensional stability) and the resin (filling the fiber insertion portions to form fiber holes). This composite approach allows the system to benefit from both materials - the reinforcement member prevents ferrule contraction while the resin-filled insertion portions maintain fiber hole positional accuracy.
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 enhances the positional accuracy of fiber holes, reduces signal loss, and suppresses deformation caused by temperature changes, ensuring precise alignment and stability of optical fibers.
Implementation Method 1
The fiber holes are formed by the resin that has entered inside the fiber insertion portions
Data Source
AI summary
A ferrule with fiber holes includes: a resin-molded portion molded by a resin; and a reinforcement member embedded in the resin-molded portion and that has a smaller linear expansion coefficient than the resin-molded portion. The reinforcement member includes fiber insertion portions that are parallel to the fiber holes. The fiber holes are formed by the resin that entered the fiber insertion portions.