Ferrule Surface Coating for Optical Fiber Bonding
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Solution Overview
Problem
The existing methods for bonding optical fibers to ferrules in fiber optic connectors face challenges such as inadequate shear strength of adhesives, poor bonding between adhesives and ferrules, and adhesives, leading to fiber pull-out and increased manufacturing costs due to time-intensive potting processes.
Innovation Solution
The use of a ferrule assembly with a coating on its inner surface to initiate an adhesive cure reaction, combining chemical and radical cure initiators to reduce curing times, and applying adhesion promoters to enhance bonding between the optical fiber and the ferrule.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional adhesives are used for bonding optical fibers to ferrules, then the bonding process is simple, but the shear strength is inadequate and fiber pull-out occurs
Solution Approach 1:
The patent applies composite materials by combining multiple coating layers (inorganic hydrolysable layer and organic adhesion promoter layer) on the ferrule surface to create a composite surface treatment system that enhances both bonding strength and reliability of fiber-to-ferrule attachment
Solution Approach 2:
The patent changes the chemical parameters of the ferrule surface by applying specific coatings (inorganic hydrolysable coating and organic adhesion promoter) that modify the surface chemistry to improve adhesive bonding characteristics and prevent fiber pull-out
2Productivity
If conventional potting processes are used for fiber optic connector manufacturing, then the bonding is adequate, but the manufacturing time is excessive and costs increase
Solution Approach 1:
The patent applies preliminary action by pre-treating the ferrule surface with inorganic hydrolysable coating and organic adhesion promoter before adhesive application, creating a surface optimized for rapid bonding that reduces subsequent curing time and increases manufacturing productivity
Solution Approach 2:
The patent changes the physical and chemical parameters of the ferrule surface through coating application, creating conditions that enable faster adhesive curing and reduce overall manufacturing cycle time while maintaining bond quality
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 adhesive cure times, enhances the bonding strength between the optical fiber and the ferrule, and improves the efficiency of fiber optic connector manufacturing by minimizing the time and cost associated with the potting process.
Implementation Method 1
providing a chemical cure initiator at an interface between the optical fiber and the ferrule; providing an adhesive composition at the interface between the optical fiber and the ferrule, the adhesive composition comprising a monomeric precursor of a methylene malonate polymer and a radical cure initiator; polymerizing the adhesive composition thereby adhering the optical fiber in the ferrule
Implementation Method 2
the adhesive composition comprising a monomeric precursor of a methylene malonate polymer and a radical cure initiator; curing of the adhesive composition wherein the adhesive is located within the fiber opening radially between the optical fiber and an inner diameter surface of the ferrule
Data Source
AI summary
Disclosed herein is a ferrule assembly. The ferrule assembly comprises a ferrule having an inner diameter surface. The ferrule assembly also comprises an adhesion promotor coating composition comprising an amine functionality, a glycidyl functionality, a thiol functionality, an oxirane functionality, or any combination thereof and a radical cure initiator. The ferrule assembly may further comprise an inorganic hydrolysable layer on the inner diameter surface. The ferrule assembly may also further comprise an adhesion promotor coating on the inorganic hydrolysable layer of a composition.