Fiber Bulge Positioning in Ferrule Bore
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Solution Overview
Problem
The existing methods for connectorization of optical fibers often result in insertion loss due to misalignment of the optical fiber core within the ferrule bore, caused by offsetting of the optical axis relative to the ferrule bore axis, leading to lateral misalignment losses.
Innovation Solution
A fiber bulge is formed at the end of the optical fiber by melting it using a radiation energy source, such as a laser, to create a protrusion that interferes with the ferrule bore, allowing for precise positioning of the fiber within the ferrule, thereby reducing insertion loss. The bulge can be symmetric or asymmetric to center or offset the fiber core as needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the optical fiber is inserted into the ferrule bore without a positioning mechanism, then the insertion process is simple, but the optical fiber core becomes misaligned with the ferrule bore axis, causing lateral misalignment losses and insertion loss
Solution Approach 1:
A bulge is formed on the optical fiber before insertion into the ferrule bore. This preliminary action creates a positioning feature that automatically centers the fiber core within the bore during insertion, eliminating misalignment issues without requiring complex adjustment mechanisms during the connectorization process.
Solution Approach 2:
The bulge acts as an intermediary element between the optical fiber and the ferrule bore. It provides a mechanical interface that translates the simple act of insertion into precise alignment, mediating between the simple insertion action and the requirement for high alignment precision.
2Manufacturing precision
If aggressive polishing is used to form the optical surface, then the end face quality can be improved, but the risk of damage to the optical fiber increases
Solution Approach 1:
The bulge is formed in advance before the polishing step. This preliminary formation of the positioning feature allows the polishing process to focus only on the end face surface without requiring aggressive material removal, thereby improving end face quality while preserving fiber integrity.
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 effectively reduces insertion loss by ensuring accurate alignment of the optical fiber within the ferrule bore, potentially eliminating the need for aggressive polishing and reducing the risk of damage during processing.
Implementation Method 1
A radiation energy source (e.g., a laser) is controlled to direct a focused energy to the end of the optical fiber extended from the front end face of the ferrule to expose and melt (i.e., deform through reflow) the end protruding from the front end face of the ferrule to form a bulge.
Implementation Method 2
A radiation energy source (e.g., a laser) is controlled to direct a focused energy to the end of the optical fiber
Data Source
AI summary
A fiber bulge (“bulge”) formed in an end of an optical fiber for positioning the optical fiber in a ferrule bore is disclosed. An energy source is controlled to direct focused energy to the end of the optical fiber extended from the front end face of the ferrule to expose and melt the end of the optical fiber into a bulge of desired geometry and size. The bulge comprises a cross-sectional region having an outer surface having a minimum outer diameter larger than the inner diameter of the ferrule bore. Thus, the optical fiber may be pulled back in the ferrule bore such that at least a portion of the outer surface of the interface region of the bulge interferes with and engages the front opening of the ferrule bore to position the fiber core within the ferrule bore.