Optical Fiber Connector Injection Molding Process

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Solution Overview

Problem

Existing methods for producing optical fiber connectors are prone to errors, difficult to monitor, and costly due to the need for precise tolerances and additional processing steps, such as cutting and polishing, which can damage the fibers and reduce optical efficiency.

Innovation Solution

A method using an injection mold with two parts, where the optical fiber end is partially melted and coated with injection molding material, eliminating the need for post-processing and ensuring a strong, durable bond between the connector element and the optical fiber, while maintaining the optical properties through controlled temperature differences and thermal insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional crimping or adhesive methods are used to hold fibers together, then the fibers can be secured, but the process is prone to errors, difficult to monitor, and increases production costs due to additional steps and rejects

Engineering Contradiction:

Improveproduction reliabilityVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple functions into a single injection-molded connector element: fiber holding, alignment, and mechanical securing are all achieved in one integrated component produced through injection molding, eliminating the need for separate crimping or adhesive application steps

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces traditional mechanical crimping systems and adhesive application systems with an injection molding process that forms the connector element directly around the fiber ends, substituting complex mechanical assembly with a single-forming operation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If additional production steps such as cutting and polishing are performed on fiber ends, then optical efficiency can be improved, but the fibers may be damaged and production costs increase

Engineering Contradiction:

Improveoptical precisionVSAvoidfiber damage

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The injection molding process performs preliminary shaping and positioning of the fiber ends within the connector element before final assembly, ensuring proper alignment and protection without requiring subsequent cutting or polishing operations that could damage the fibers

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If traditional connector production methods are used, then connectors can be produced, but the process is time-consuming and costly due to multiple production steps

Engineering Contradiction:

Improveproduction simplicityVSAvoidproduction speed

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

Multiple production operations (molding, fiber securing, alignment feature creation) are merged into a single injection molding cycle, allowing all connector elements to be produced simultaneously in one batch without sequential processing steps

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The injection molding process automatically performs all necessary forming and securing operations without requiring manual intervention or additional processing steps, making the manufacturing process self-contained and highly efficient

Inventive Principle:

Principle #25Self-service

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 results in a simple, quick, and cost-effective production of optical fiber connectors with improved light conductance and mechanical durability, reducing production costs and maintaining the optical integrity of the fibers without the need for additional processing steps.

Implementation Method 1

An injection mold comprising two parts is used, the first of which has a first cavity into which the injection molding material is injected

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 2

the optical fiber end is partially melted and coated with injection molding material

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

maintaining the optical properties through controlled temperature differences and thermal insulation

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20240208167A1Optical fiber connector and production method thereof

Publication Date: 2024.06.27 HELLA GMBH & CO KGAA

AI summary

An optical fiber has an individual fiber and a sheath. The sheath on one end is stripped, such that a length of at least one end of the individual fiber is exposed. An injection mold has a first part first part that contains a first cavity into which an injection molding material is injected. A second part of the mold contains a second cavity in which at least one end of the optical fiber is placed. The end of the optical fiber is secured in the second cavity. A second length of the exposed end of the fiber extends into the first cavity. The injection molding material is injected into the first cavity to obtain a connector element. The at least one exposed end of the optical fiber is at least partially coated. The first part and second part of the mold are brought to different temperatures.