Optical Fiber Connector Lens Atomization
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Solution Overview
Problem
The production of optical fiber connectors is labor-intensive and time-consuming due to the need for individual handling and grinding of optical fibers, which can lead to increased labor costs and inefficiencies.
Innovation Solution
A method using a casting mold with a protective layer and an atomization facility to automate the production of optical fiber connectors, where plastic material is fed into the mold, solidified, and then ground to form a lens on the fiber ends, enhancing the manufacturing process efficiency and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual handling and grinding of optical fibers is performed, then manufacturing precision can be maintained, but productivity decreases and labor time increases
Solution Approach 1:
Multiple optical fibers are bundled together and handled as a single unit through the casting mold, which simultaneously bonds multiple fibers and forms a unified structure. This merging approach maintains individual fiber precision while enabling batch processing, thereby resolving the contradiction between manufacturing precision and productivity.
Solution Approach 2:
The casting mold performs preliminary bonding and alignment of multiple optical fibers before the grinding process. By pre-positioning and securing the fibers in the correct configuration, the subsequent grinding operation can be performed more efficiently on the already-aligned bundle, improving overall productivity without sacrificing precision.
2Productivity
If automated casting and atomization processes are used, then productivity increases, but device complexity increases
Solution Approach 1:
The casting mold serves multiple functions simultaneously: it bonds multiple optical fibers together, provides structural support, enables automated handling, and facilitates the atomization process. This multi-functionality reduces the need for separate devices for each operation, thereby increasing productivity while limiting the growth of device complexity.
Solution Approach 2:
The plastic material acts as an intermediary substance that enables automated processing. It bonds the optical fibers together in a controllable manner, provides a uniform surface for atomization, and creates a structure that can be easily handled by automated equipment. This intermediary material allows complex automated processes to work effectively without requiring equally complex device configurations.
3Strength
If multiple plastic layers are used in the casting mold, then connector strength is improved, but manufacturing process complexity increases
Solution Approach 1:
Different plastic layers are used with specific properties tailored to local requirements: the first plastic layer provides bonding and protection, while the second plastic layer adds structural reinforcement. This local differentiation of material properties optimizes connector strength at each layer without requiring complex overall process design, as each layer serves a specific functional purpose.
Solution Approach 2:
The use of multiple plastic layers creates a composite structure that combines the advantages of different materials. The first layer (softer plastic) provides flexibility and bonding, while the second layer (harder plastic) provides structural strength and rigidity. This composite approach improves overall connector strength while maintaining a relatively simple manufacturing process, as the layers can be applied sequentially using standard casting techniques.
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 significantly reduces labor and time required for producing optical fiber connectors, improving their reliability and efficiency by automating the process and enhancing the alignment and strength of the connectors.
Implementation Method 1
atomizing lens material to the end of the at least one optical fiber assembly so as to form a lens on the end
Implementation Method 2
Solidifying the plastic material so as to form a plastic portion which solidifiedly bonds the at least one optical fiber assembly
Data Source
AI summary
A method for making an optical fiber connector includes the following steps: Providing a casting mold having at least one casting cavity, and arranging at least one optical fiber assembly in the at least one casting cavity; Feeding plastic material into the at least one casting cavity; Solidifying the plastic material so as to form a plastic portion which solidifiedly bonds the at least one optical fiber assembly, where an end of the at least one optical fiber assembly emerges from the plastic portion, then removing a lower mold plate of the casting mold; Using a hard grinding disk to grind the end of the at least one optical fiber assembly; and Disposing the casting mold into an atomization facility, and atomizing lens material to the end of the at least one optical fiber assembly, acting with a manner of epicyclic gearing revolving therearound and with their own axes, so as to form a lens on the end of the at least one optical fiber assembly such that the lens is heated and solidified. Thereby, efficacy in producing optical fiber connectors can be improved. Also disclosed is a structure of the optical fiber connector, thus reliability of automated production of optical fiber connectors can be increased.