Ferrule Structure With Unit Holes For Lens Alignment
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Solution Overview
Problem
Existing ferrule structures for optical fiber connections face challenges in achieving precise alignment between lenses and optical fibers due to complex manufacturing processes and high precision requirements, leading to increased costs and difficulty in assembly.
Innovation Solution
A ferrule structure with unit holes and lens units, where the lens units are molded from resin capable of transmitting optical signals and inserted into the unit holes, allowing for precise alignment and simplified manufacturing, with features such as recessed parts and flange parts for protection and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the ferrule body and lens array are molded with high precision and assembly error is suppressed, then alignment between optical fiber and lens is improved, but manufacturing difficulty increases and manufacturing cost increases
Solution Approach 1:
The invention divides the lens array into individual lens units, each attached to a separate optical fiber. This segmentation allows each lens unit to be independently positioned and aligned, eliminating the need for high-precision multi-component molding and assembly. The ferrule body with unit holes provides a simple positioning structure that guides each lens unit into place, significantly reducing manufacturing difficulty while maintaining alignment precision.
2Manufacturing precision
If the lens plate includes alignment sockets and optical fiber end parts are inserted, then alignment between lenses and optical fiber is improved, but the lens plate structure becomes complicated and manufacturing difficulty increases
Solution Approach 1:
The invention extracts the alignment function from the lens plate structure and relocates it to the ferrule body through unit holes. Each unit hole serves as an individual alignment guide for its corresponding lens unit, eliminating the need for a complicated lens plate with integrated alignment sockets. This separation of alignment function simplifies the overall structure while maintaining precise alignment capability.
3Reliability
If multiple lenses are aligned with multiple optical fibers using a lens array, then optical connection is achieved, but manufacturing complexity and assembly error accumulate
Solution Approach 1:
The invention performs preliminary alignment by attaching each lens to its corresponding optical fiber before insertion into the ferrule. The unit holes in the ferrule body provide pre-established positioning guides that ensure correct alignment during insertion. This preliminary preparation of lens units eliminates the need for complex post-assembly alignment procedures, reducing assembly error accumulation while ensuring reliable optical connections.
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
Enables high-precision alignment of lenses with optical fibers, reduces manufacturing complexity and costs, and minimizes damage to lens parts during assembly, while maintaining optical signal quality.
Implementation Method 1
molded from a resin capable of transmitting an optical signal
Data Source
AI summary
A ferrule structure includes a ferrule including a plurality of unit holes, and a plurality of lens units, wherein each lens unit includes a lens part attached to an end part of an optical fiber, and each lens unit is molded from a resin for transmittance an optical signal, and each lens unit is to be inserted in one of the unit holes.