Optical Fiber Connector Assembly Tool for Precision Protrusion Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional remote grip optical fiber connectors experience issues with optical losses and reflections due to temperature-induced gaps caused by differences in the coefficient of expansion between the fiber and the ferrule, leading to poor insertion loss and significant back reflection, and require additional polishing steps to ensure secure contact.
Innovation Solution
An assembly tool that includes a base with a connector mount and a cradle holding a shaped ferrule with a recessed or stepped end face to set a precise protrusion length of the optical fiber, allowing for reliable and repeatable fiber insertion and termination, potentially eliminating the need for final polishing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a coplanar/flush polish is used after fiber insertion, then the fiber tip is positioned at the ferrule end face, but temperature changes cause gaps due to coefficient of expansion differences leading to poor insertion loss and significant back reflection
Solution Approach 1:
The patent applies preliminary action by pre-setting the fiber protrusion length before final assembly. A shaped ferrule with a precisely controlled recess depth is used to define the exact protrusion distance of the fiber tip beyond the ferrule end face. This pre-established geometric constraint ensures that when the connector is assembled and subjected to temperature variations, the fiber maintains a consistent protrusion that prevents gap formation, thereby resolving the thermal expansion reliability issue while maintaining manufacturing precision.
2Reliability
If a technician performs a field polish to create a protruding fiber terminal end, then secure physical contact is achieved, but the process produces a range of protrusion lengths requiring additional polishing steps
Solution Approach 1:
The shaped ferrule performs a self-service function by automatically defining and controlling the fiber protrusion length through its pre-manufactured recess geometry. When the fiber is inserted and secured in the connector, the shaped ferrule's recess depth precisely determines the protrusion distance without requiring manual polishing or adjustment. This self-defining mechanism ensures consistent protrusion lengths and reliable physical contact while eliminating the need for additional polishing steps, thus resolving both the reliability and precision contradictions.
3Productivity
If no final polishing is done to the fiber, then the protrusion setting step defines the final protrusion, but consistent protrusion length must be ensured through precise setting
Solution Approach 1:
The patent applies preliminary action by pre-configuring the shaped ferrule with a precisely controlled recess depth during manufacturing. This pre-established geometric feature defines the exact fiber protrusion length before the fiber insertion and assembly process. By transferring this precision from the shaped ferrule manufacturing stage to the final assembly, the system eliminates the need for post-assembly polishing while ensuring consistent protrusion lengths, thus resolving the contradiction between productivity improvement and manufacturing precision maintenance.
Data Source
AI summary
An assembly tool is provided for installing an optical fiber in an optical fiber connector having a known length of fiber extending from the connector ferrule after termination of the optical fiber connector. The assembly tool includes a base having a connector mount disposed on a first end thereof and a cradle that holds a shaped ferrule disposed near the second end of the base, such that shaped ferrule is resiliently held within the cradle. The connector mount is configured to receive and secure the optical fiber connector to the base.