Optical Fiber Connector with Intact Primary Coating
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Solution Overview
Problem
The existing methods for optical interconnections on circuit boards are hindered by the fragility of optical fibers after stripping their primary coating, making handling difficult and increasing manufacturing costs, while current optical-electrical PCBs and components are not yet commercially available, limiting high-speed data transfer rates.
Innovation Solution
A connector for optical fibers with a ferrule that glues the fibers directly, maintaining their primary coating, which reduces handling issues and manufacturing costs by using fibers with tighter diameter tolerances, allowing for easier mounting without stripping the coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the primary coating of optical fibers is stripped before gluing to the ferrule, then the fibers can be glued directly to the ferrule surface, but the fibers become extremely fragile and handling becomes extremely difficult
Solution Approach 1:
The ferrule is prepared in advance with a matching layer (epoxy or UV-curing compound) on its inner surface, which is designed to bond directly with the primary coating of the optical fibers. This preliminary preparation eliminates the need to strip the fibers, as the bonding interface is pre-configured to accept the fiber's primary coating intact.
Solution Approach 2:
The invention uses a consumable bonding layer (epoxy or UV-curing compound) applied to the ferrule that serves a single purpose: to bond the fibers to the ferrule. This disposable layer simplifies the process by providing a ready-made bonding interface that eliminates complex fiber preparation steps.
2Ease of manufacture
If the primary coating of optical fibers is stripped before gluing, then direct gluing to ferrule is possible, but manufacturing costs increase due to handling difficulties and lower yield
Solution Approach 1:
The ferrule is pre-coated with a bonding layer designed to match the fiber's primary coating, eliminating the need for stripping. This preliminary preparation simplifies the manufacturing process, reduces handling time, and improves yield by avoiding the fragility issues associated with stripped fibers.
Solution Approach 2:
The invention changes the bonding interface parameters by introducing a matching layer with specific adhesive properties that are optimized to bond with the fiber's primary coating. This parameter change (adding the matching layer) transforms the process from one requiring fiber stripping to one that preserves the coating, thereby improving productivity and reducing costs.
3Ease of manufacture
If optical fibers with tighter diameter tolerances are used, then direct gluing without stripping becomes feasible, but fiber selection is more restricted
Solution Approach 1:
The invention changes the critical parameter from fiber diameter tolerance to bonding layer compatibility. By introducing a matching layer with adjustable adhesive properties, the system can accommodate a broader range of fiber types and coatings, thereby maintaining versatility while enabling direct gluing without stripping.
Solution Approach 2:
The matching layer acts as an intermediary between the ferrule and the optical fiber's primary coating. This intermediary layer compensates for variations in fiber dimensions and coating properties, allowing direct gluing of fibers with intact coatings while maintaining bonding reliability across different fiber types.
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 approach simplifies the manufacturing process, reduces overall costs, and maintains acceptable optical insertion loss, making high-speed circuit boards more economically viable with available commercial components.
Implementation Method 1
a ferrule into which the optical fibers are glued directly with their outer cladding
Data Source
AI summary
A connector for one or more optical fibers has a ferrule into which the optical fibers are glued directly with their outer cladding. No stripping of the fibers is required any longer before gluing them to the ferrule and thus, the difficulty of the fragility of the stripped fibers is overcome. The fibers are special fiber having a primary coating with smaller tolerances of ±2 microns. The fibers are arranged on a flexible foil which forms an optical overlay for a printed circuit board.