Ferrule Reshaping for Direct Locking Optical Fibers
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Solution Overview
Problem
The existing methods for securing optical fibers within ferrules in optical fiber connectors are costly due to the use of bonding agents and complex processing steps, and there is a need to reduce manufacturing and operating costs while ensuring effective fiber insertion.
Innovation Solution
The use of laser treatment to modify the physical structure of the ferrule by creating protrusions or altering the shape of the ferrule bore, which secures the optical fiber without the need for adhesives, by applying a laser beam to the inner surface of the ferrule bore to create compressive forces that lock the fiber in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bonding agents and complex processing steps are used to secure optical fibers within ferrules, then the fiber insertion effectiveness is improved, but the manufacturing and operating costs increase
Solution Approach 1:
The patent removes the bonding agent from the system entirely and replaces it with a mechanically self-locking ferrule structure. The extraction principle is applied by eliminating the adhesive material and using only the ferrule's structural features (tapered bore, outer diameter expansion) to achieve fiber retention, thereby reducing material costs and simplifying the manufacturing process.
Solution Approach 2:
The patent replaces the chemical bonding mechanism (adhesive) with a mechanical locking mechanism. The ferrule's tapered bore and expansion features create direct mechanical engagement with the fiber, substituting chemical adhesion with physical interlocking through compression and friction forces generated by the tapered geometry.
2Strength
If bonding agents are used to secure optical fibers, then the fiber is held firmly in place, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The bonding agent is completely removed from the assembly process. The ferrule structure itself provides the holding force through its tapered bore and expansion features, eliminating the need for separate adhesive application steps and reducing process complexity while maintaining fiber retention strength.
Solution Approach 2:
The ferrule structure is designed to automatically secure the fiber through its own geometric features without requiring external bonding agents. The tapered bore and expansion characteristics enable the ferrule to self-lock the fiber in place through mechanical compression, making the system self-sufficient and simplifying the assembly process.
3Ease of manufacture
If traditional ferrule structures are used, then the manufacturing process is simpler, but the fiber securing mechanism is less effective and requires additional materials
Solution Approach 1:
The ferrule is designed with localized geometric features (tapered bore section, specific outer diameter expansion) that concentrate the securing function in particular regions. This local quality approach allows the ferrule to provide effective fiber retention through targeted structural modifications rather than requiring complex overall designs or additional materials.
Solution Approach 2:
The patent modifies key geometric parameters of the ferrule, specifically the bore angle (20-45 degrees) and outer diameter expansion (0.002-0.005 inches), to optimize the mechanical locking effect. These parameter changes enable effective fiber securing through controlled compression and friction forces, improving reliability while maintaining manufacturing simplicity.
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 method reduces material costs and simplifies the assembly process by eliminating the need for bonding agents, while providing a secure and effective locking mechanism that maintains the optical fiber within the ferrule, achieving a pull force of at least 2 pounds-force as measured by IEC61753.
Implementation Method 1
applying a laser beam to the inner surface of the ferrule bore to create compressive forces that lock the fiber in place
Implementation Method 2
applying a laser beam to the inner surface of the ferrule bore to create compressive forces that lock the fiber in place
Implementation Method 3
the ferrule is heated to expand the ferrule and ferrule bore and to melt a portion of the bonding agent
Implementation Method 4
the ferrule cools to room temperature, thereby, contracting the ferrule, and locking the optical fiber within the ferrule
Data Source
AI summary
The present disclosure relates to laser treatment of a ferrule to secure an optical fiber within a ferrule bore. In particular, the laser treatment modifies the physical structure of the ferrule to aid in securing the optical fiber within the ferrule bore.