Optical Fiber Connector Ferrule With Eliminated Insertion Holes
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Solution Overview
Problem
Conventional optical fiber networks with a 12-count fiber basis result in significant waste, as only 8 out of 12 fibers are utilized in faster networks like 40G and 100G, leading to costly and inefficient data transmission due to unused fibers.
Innovation Solution
The optical fiber connector system reduces fiber count by omitting middle fibers, utilizing a ferrule with fiber-shaped members and insertion holes to ensure uniform polishing and prevent abrasive penetration, allowing for 100% end-to-end fiber utilization with an 8-count fiber basis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a 12-count fiber basis is used in conventional networks, then the fiber structure is standardized and compatible with traditional connectors, but 4 out of 12 fibers remain unused in 40G and 100G networks, resulting in 33% fiber waste
Solution Approach 1:
The patent extracts and removes the unused middle four fiber insertion holes from the traditional 12-count ferrule structure, creating an 8-count ferrule that only contains the necessary fiber positions for 40G and 100G networks. This eliminates the 33% fiber waste by physically removing the unnecessary components rather than leaving them as unused placeholders.
Solution Approach 2:
The patent segments the fiber count from the traditional 12-count basis into a customized 8-count configuration, dividing the ferrule structure to match the actual network requirements. This segmentation allows the connector to be optimized for specific applications without being constrained by the traditional 12-count standard.
2Loss of substance
If middle four fiber insertion holes are omitted to reduce fiber count, then fiber waste is eliminated, but unused fiber insertion holes create risks of abrasive penetration and non-uniform polishing
Solution Approach 1:
The patent converts the potential harm of unused fiber insertion holes (abrasive penetration and polishing defects) into a benefit by completely removing these holes from the structure. Instead of trying to protect against the harmful effects, the design eliminates the source of the problem entirely, transforming what would be a vulnerability into a strength of the simplified structure.
3Speed
If converters or conversion modules are used to upgrade slower networks to faster networks, then network speed can be increased, but manufacturing and maintenance costs increase significantly
Solution Approach 1:
The patent changes the fundamental parameter of fiber count from the traditional 12-count to an optimized 8-count configuration. This parameter change allows direct compatibility with 40G and 100G networks without requiring conversion modules or adapters, thereby reducing manufacturing and maintenance costs while maintaining high data transfer speeds.
4Manufacturing precision
If all 12 fiber positions are polished uniformly, then the ferrule surface is consistent, but time and resources are wasted polishing four unused fiber positions
Solution Approach 1:
The patent extracts the unnecessary fiber insertion holes from the ferrule structure, so that only the eight positions requiring fibers are present. This eliminates the waste of polishing time and resources on unused positions while maintaining uniform polishing quality across all actual fiber positions, as the polishing process is applied only to necessary components.
Data Source
AI summary
An optical fiber with a connector includes a first connector and a plurality of optical fibers attached to the first connector. The first connector includes: at least one fiber-shaped member; and a ferrule including a first end surface and a second end surface arranged in a first direction, and a holding portion holding the optical fibers and the fiber-shaped member. In the holding portion, a plurality of fiber insertion holes extending from the first end surface in the first direction is formed such that the optical fibers and the fiber-shaped member are insertable thereinto. One end of the optical fiber and one end of the fiber-shaped member are held by the holding portion in a state of being inserted into the fiber insertion hole. The optical fiber extends to the outside of the ferrule. The other end of the fiber-shaped member is located inside the ferrule.