Ferrule Reshaping for Core-to-Ferrule Concentricity Error Correction
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Solution Overview
Problem
Optical fiber connectors suffer from core-to-ferrule concentricity errors, leading to increased insertion loss due to misalignment of optical fibers, which existing technologies have not effectively addressed.
Innovation Solution
A method involving measuring the distance from the true center of the ferrule to the optical fiber core and reshaping the ferrule to redefine its center, thereby reducing the core-to-ferrule concentricity error by selectively removing or adding material to the ferrule's outer surface, potentially using abrasive belts or laser beams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the ferrule is reshaped to reduce core-to-ferrule concentricity error, then coupling efficiency is improved, but circularity error of the ferrule increases
Solution Approach 1:
The patent applies selective material removal or addition at specific locations on the ferrule outer surface rather than uniform modification. By targeting only the regions that contribute to concentricity error (based on measured offset distance δ and angular direction θ), the method reduces core-to-ferrule misalignment while minimizing overall circularity degradation.
Solution Approach 2:
The patent modifies the ferrule geometry by changing the outer surface parameters (radius, shape) in specific angular directions. The reshaping process adjusts local radial dimensions to compensate for core offset, transforming the ferrule from a perfect circle to an intentionally modified shape that centers the core relative to the outer surface reference.
2Manufacturing precision
If material is selectively removed or added to reshape the ferrule, then core-to-ferrule concentricity error is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent replaces complex multi-step mechanical machining processes with laser-based material removal or deposition. The laser method allows precise, computer-controlled modification of the ferrule outer surface based on measured error parameters, simplifying the manufacturing workflow while achieving high precision concentricity correction.
Solution Approach 2:
The ferrule reshaping process uses the ferrule's own outer surface geometry as the reference framework for correction. By measuring the actual outer surface and using it to determine where material should be removed or added, the process self-corrects without requiring external master references or complex alignment fixtures.
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 significantly reduces the core-to-ferrule concentricity error, resulting in improved coupling efficiency and lower insertion loss between optical fibers.
Implementation Method 1
selectively removing or adding material to the ferrule's outer surface, potentially using abrasive belts or laser beams
Implementation Method 2
selectively removing or adding material to the ferrule's outer surface, potentially using abrasive belts or laser beams
Data Source
AI summary
Methods of reshaping ferrules (20) used in optical fiber cables assemblies (170) are disclosed. The reshaping methods reduce a core-to-ferrule concentricity error (E), which improves coupling efficiency and optical transmission. The methods include measuring a distance (δ) and angular direction (θ) from a true center (30) of the ferrule to the core (46), wherein the true center (30) is based on an outer surface (26) of the ferrule. The methods also include reshaping at least a portion (26P) of the ferrule (20) to define a new true center (30′) of the ferrule (20) and reduce the distance (δ). A variety of reshaping techniques are also disclosed.