Optical Fiber Bundle Ferrule Layout for Tapered Fiber Protection

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing optical-fiber bundle structures suffer from bending loss and breakage due to stress during manufacturing, which affects yield and production throughput.

Innovation Solution

The optical-fiber bundle structure features a ferrule with a fiber accommodating portion divided into first and second accommodating portions of different diameters, where the optical fibers have a tapered portion connecting them, and the tapered portions of adjacent fibers are located in separate regions, reducing bending and breakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If optical fibers are accommodated in a conventional ferrule structure during manufacturing, then the fibers can be assembled, but the fibers suffer from bending loss and breakage due to stress

Engineering Contradiction:

Improvefiber integrityVSAvoidproduction throughput

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The ferrule is segmented into multiple accommodating portions with different inner diameters along the longitudinal direction. Each accommodating portion has a different inner diameter to correspond to different diameter portions of the optical fibers, allowing the fibers to be accommodated in a stress-free state while maintaining structural integrity during manufacturing

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the ferrule have different local qualities (inner diameters) matched to different portions of the optical fibers. The first accommodating portion has a smaller inner diameter for the first diameter portion of fibers, while the second accommodating portion has a larger inner diameter for the second diameter portion, preventing bending stress at each location

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If optical fibers with tapered portions are used, then connection flexibility is improved, but the fibers are more susceptible to bending loss and breakage

Engineering Contradiction:

Improveconnection flexibilityVSAvoidfiber strength

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The ferrule structure is designed beforehand to accommodate the tapered portions of the optical fibers in a stress-free manner. The accommodating portions provide protective support for the tapered portions, cushioning them against bending stress and breakage before assembly is completed

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The optical fibers with tapered portions are nested within the ferrule structure, with each fiber's different diameter portions fitting into corresponding accommodating portions. This nested arrangement protects the vulnerable tapered portions while maintaining connection flexibility

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS12481106B2Optical-fiber bundle structure, optical connection structure, and method of manufacturing optical-fiber bundle structure

Publication Date: 2025.11.25 SUMITOMO ELECTRIC INDUSTRIES LTD

AI summary

In each of the plurality of optical fibers, a second diameter portion has a diameter larger than that of a first diameter portion. A tapered portion connects the first diameter portion and the second diameter portion by a tapered surface. In a fiber accommodating, a second accommodating portion has an inner diameter larger than that of a first accommodating portion. Each first diameter portion is located in the first accommodating portion. Each second diameter portion is located in the second accommodating portion. The second accommodating portion includes a plurality of regions divided by imaginary planes perpendicular to the first direction. The tapered portions of the optical fibers adjacent to each other among the plurality of optical fibers are located in the different regions among the plurality of regions.