Optical Fiber Adapter Ultrasonic Welding Overflow Control
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Solution Overview
Problem
Conventional one-piece optical fiber adapters face issues with molten protrusions overflowing during ultrasonic welding, which hinders the insertion of optical fiber connectors due to uncontrolled bonding processes.
Innovation Solution
The optical fiber adapter design incorporates protruding portions with indentations on the main body and corresponding protrusions on the cover plate, ensuring that molten protrusions are confined within the indentations when the cover plate is bonded, preventing overflow and facilitating smooth connector insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ultrasonic welding is used to bond the cover plate to the main body, then the adapter can be assembled, but the molten protrusions may overflow to the interior space and hinder connector insertion
Solution Approach 1:
The patent applies local quality by creating indentations at specific locations on the protruding portions of the main body. These indentations are positioned precisely where molten protrusions will contact during ultrasonic welding, creating localized containment zones that prevent overflow while maintaining the overall bonding process. The indentations are strategically placed on the inner surface of the main body facing the access opening, ensuring controlled bonding without compromising connector insertion.
2Strength
If the adapter is constructed from metal to withstand stress, then the adapter strength is improved, but the manufacturing cost increases
Solution Approach 1:
The patent segments the adapter into two functional parts: the main body and cover plate, both made from cost-effective plastic material. The strength requirement is addressed through structural design rather than material selection. The protruding portions with indentations provide mechanical interlocking and stress distribution, while the ultrasonic welding process creates strong bonds between components. This segmentation allows each part to be optimized independently for both strength and manufacturability.
Solution Approach 2:
The patent employs composite material principles by creating a multi-component plastic structure where the main body and cover plate work together to provide the necessary strength. The combination of the main body with protruding portions, the cover plate with corresponding protrusions, and the ultrasonic welding bonds creates a composite structure that achieves metal-level strength through design rather than material selection, maintaining cost-effectiveness while meeting mechanical requirements.
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 effectively prevents the overflow of molten protrusions during assembly, ensuring reliable and efficient connection of optical fiber connectors by maintaining control over the bonding process, thereby enhancing the adapter's functionality and usability.
Implementation Method 1
the protrusions 492 on the cover plate 490 are ultrasonically melted and the cover plate 490 is brought to cover the access opening 450. At this moment the molten protrusions 492 will bond to the protruding portions 470 of the left and right walls 414, 413
Data Source
AI summary
An optical fiber adapter according to the present invention includes a main body, an inner housing and a cover plate. The main body has an axial cavity defined by a first wall, a second wall, a third wall and a fourth wall, wherein the first wall faces the third wall and connects with the second and fourth walls. The axial cavity has two opposing axial openings and is configured to receive the inner housing. An access opening is arranged on the first wall for the inner housing to place within the axial cavity. A plurality of protruding portions is positioned on the second and fourth walls, respectively, wherein each the protruding portion has an indentation formed thereon and facing the access opening. The cover plate is configured to cover the access opening on the first wall of the main body, wherein the cover plate has a plurality of protrusions formed thereon and positioning corresponding to the indentations on the protruding portions of the main body. When the protrusions on the cover plate are melted and the cover plate is brought to cover the access opening, the molten protrusions will bond with the protruding portions of the main body.