Optical Fiber Coating Removal via Heated Ferrule Insertion
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Solution Overview
Problem
Current methods for removing polymer coatings from optical fibers to prepare them for fiber optic connectors are inefficient, costly, and prone to damaging the fibers, as they require complex equipment, hazardous chemicals, or generate debris.
Innovation Solution
Thermal removal of optical fiber coatings by inserting the fiber through a heated ferrule, which changes the coating to a non-solid state, allowing precise positioning and secure attachment within the ferrule without the need for mechanical stripping or hazardous chemicals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hot-gas stripping is used to remove coating, then coating removal is achieved, but considerable debris is created and heat-sensitive materials may be overheated
Solution Approach 1:
The patent replaces the hot-gas mechanical/thermal stripping system with a precision mechanical blade system that physically cuts the coating without generating debris or overheating. The blade mechanically separates the coating from the fiber through controlled cutting action rather than thermal decomposition.
Solution Approach 2:
The patent introduces a support body as an intermediary element that holds the blade at a precise distance from the fiber surface. This intermediary ensures the blade cuts only the coating without contacting or damaging the underlying fiber, mediating between the cutting action and the fiber protection requirements.
2Reliability
If mechanical stripping with blades is used, then coating removal is achieved, but optical fiber may be damaged and blades require inspection and replacement
Solution Approach 1:
The support body acts as an intermediary that precisely positions the blade relative to the fiber, maintaining a fixed gap that prevents the blade from contacting and damaging the fiber while still allowing effective coating removal. This intermediary structure eliminates the need for continuous blade inspection and replacement.
Solution Approach 2:
The patent changes the operational parameter from direct blade-to-fiber contact to blade-at-distance-from-fiber cutting. By modifying the spatial parameter (distance between blade and fiber), the system achieves coating removal without fiber damage, eliminating the harmful effects of mechanical stripping.
3Reliability
If chemical stripping is used to remove coating, then coating removal is achieved, but extensive environmental protection procedures and safety measures are required
Solution Approach 1:
The patent replaces the chemical stripping process with a mechanical blade cutting system. This substitution eliminates the need for chemicals entirely, removing all associated environmental protection procedures, safety equipment, and handling requirements while maintaining effective coating removal.
Solution Approach 2:
The patent uses a simple, inexpensive blade that can be easily replaced if needed, rather than requiring complex chemical systems. The mechanical blade is a simple object that eliminates the need for expensive safety infrastructure and environmental protection measures associated with chemical processes.
4Reliability
If laser stripping is used to remove coating, then coating removal is achieved, but complex three-dimensional mirrors or specialized equipment are required
Solution Approach 1:
The patent replaces the complex laser system with a simple mechanical blade mounted on a support body. This substitution eliminates the need for three-dimensional mirrors, laser beam delivery systems, and specialized equipment, using instead a straightforward mechanical cutting approach.
Solution Approach 2:
The patent extracts only the essential function of coating removal from the complex laser system, achieving it through a simple blade that cuts the coating. This extraction eliminates all the unnecessary complexity of laser delivery systems while maintaining the core coating removal capability.
5Manufacturing precision
If coating is removed prior to ferrule insertion, then precise fiber positioning is achieved, but stripped fiber is vulnerable to damage from particulates
Solution Approach 1:
The patent performs the coating removal action at the precise moment when the fiber is being inserted into the ferrule, rather than removing the coating beforehand. This preliminary timing ensures the fiber remains protected by its coating until it reaches the protective ferrule environment, eliminating vulnerability to particulate damage.
Solution Approach 2:
The patent merges the coating removal operation with the ferrule insertion operation into a single integrated process. The blade removes the coating only as the fiber passes through the ferrule opening, combining two operations that were previously separate and eliminating the vulnerable intermediate state.
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 reduces manufacturing time, minimizes fiber damage, and ensures precise alignment and secure attachment, enhancing the reliability and efficiency of fiber optic connections.
Implementation Method 1
heating the ferrule above the initial temperature with a heating device
Implementation Method 2
inserting a coated end portion of an optical fiber through the rear opening of the ferrule while the ferrule is heated above the initial temperature sufficient to change a coating on the coated end portion of the optical fiber to a non-solid state
Data Source
AI summary
Thermal removal of optical fiber coatings by insertion through heated ferrules to form ferrule assemblies for fiber optic connectors, and related assemblies are disclosed. An optical fiber includes a glass fiber, having a cladding and core, surrounded by a protective coating. By removing the coating at an end portion of the optical fiber, the end portion may be precisely positioned and secured within a ferrule to enable reliable optical communications. The coating may be thermally removed, or substantially thermally removed, by inserting the optical fiber through a rear opening of the ferrule which has been heated above a temperature sufficient to change the coating to a non-solid state. In this manner, the coating may be efficiently removed from the end portion of the optical fiber while being inserted into the ferrule bore of the ferrule to enable efficient forming of a ferrule assembly for a fiber optic connector.