Optical Fiber Connector with Hardened Coated Physical Contact
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Solution Overview
Problem
Current optical fiber connectors face challenges in achieving low back reflection and maintaining precise alignment and orientation, especially at higher data rates, due to fiber properties and connector tolerances, which complicates the mating process and increases the risk of insertion loss.
Innovation Solution
The use of thermally shaped optical fiber contacts coated with a thin film of hard materials like Al2O3 (corundum) for low reflection, where the film's optical thickness is between 0.10 and twice the operating wavelength, and the application of a quick connect device for efficient coating and assembly, allowing for low back reflection without the need for keyed orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If angle polishing is used to reduce back reflection, then back reflection is reduced, but connector orientation complexity increases due to keyed requirements
Solution Approach 1:
The patent changes the parameter of contact surface geometry from angled to spherical curvature, and introduces a new parameter - thin film coating with specific optical thickness (0.05 to 0.50 wavelength). This combination achieves low back reflection through optical interference in the coating while maintaining mechanical symmetry, eliminating the need for keyed orientation.
Solution Approach 2:
The patent creates a composite structure by coating the optical contact surface with a thin film layer having different refractive index properties than the fiber core. This composite material system (fiber core + thin film coating) provides both mechanical durability and optical performance, achieving low back reflection without requiring angled geometry.
2Manufacturing precision
If fiber properties and connector tolerances are tightened to achieve precise alignment, then alignment precision is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies a protective thin film coating to the optical contact surface before mating, which cushions and protects the precise spherical geometry from damage during handling and mating operations. This beforehand protection maintains alignment precision without requiring excessive manufacturing tolerances, as the coating compensates for minor variations.
3Strength
If physical contact surfaces are made harder for durability, then connector strength is improved, but back reflection increases without proper coating optimization
Solution Approach 1:
The patent creates a composite structure by coating the optical contact surface with a thin film layer having different refractive index properties than the fiber core. This composite material system (fiber core + thin film coating) provides both mechanical durability and optical performance, achieving low back reflection without requiring angled geometry.
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 solution provides optical fiber connectors with low back reflection and enhanced durability, reducing insertion loss and maintaining alignment without the need for keyed orientation, suitable for harsh environments and high data rates.
Implementation Method 1
The physical contact is coated with a thin film of hard materials like Al2O3 (corundum) for low reflection, where the film's optical thickness is between 0.10 and twice the operating wavelength
Implementation Method 2
A vacuum is applied to the termini. The physical contact is coated with a protective film while the vacuum is applied
Implementation Method 3
The optical fiber has a free end forming a physical contact. The physical contact is thermally shaped
Data Source
AI summary
A fiber optic connector for use with a fiber optic network having at least one predetermined operating wavelength is provided. First housing contains at least one optical fiber. The optical fiber has a free end forming a physical contact. The physical contact is coated with a protective film. The optical thickness of the protective film is at least 0.10 of the operating wavelength of the fiber optic network. Preferably, the physical contact is thermally shaped. Also preferably, the optical fiber is attached to a quick connect device forming a termini. The physical contact of the optical fiber can be readily coated with the protective film by placing the termini in a vacuum chamber.