Fiber Optic Adapter Mechanical Riveting Assembly
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Solution Overview
Problem
Traditional fiber optic adapters are prone to mechanical failure due to weaknesses in ultrasonic welding joints and complex assembly processes, especially when handling larger or longer fiber connectors.
Innovation Solution
A fiber optic adapter with a one-piece housing and a sleeve-retaining insert, molded for mechanical riveting instead of ultrasonic welding, featuring extensions and rivets for alignment and assembly, resulting in a stronger and more reliable assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ultrasonic welding is used to join adapter housing halves, then the components can be assembled, but the welding joint creates a point of weakness that can break under shear or bending stresses
Solution Approach 1:
The adapter housing is divided into two separate halves that are joined together, allowing for modular assembly while maintaining structural integrity through the riveting process
Solution Approach 2:
The ultrasonic welding process is replaced with a mechanical riveting system that uses metal or plastic rivets to join the housing halves, eliminating the thermal and process-sensitive welding step while creating a mechanically robust connection
2Ease of manufacture
If ultrasonic welding is used to assemble adapter components, then the housing can be joined, but the process is extremely process-sensitive requiring careful control of temperature, humidity, and machine parameters
Solution Approach 1:
The complex ultrasonic welding process with its multiple controlled parameters (temperature, humidity, machine settings) is replaced with a simple mechanical riveting process that does not require thermal control or sensitive process parameters
Solution Approach 2:
The process parameters are fundamentally changed from thermal and environmental controls (ultrasonic welding) to simple mechanical insertion and deformation forces (riveting), eliminating the need for careful control of temperature and humidity
3Adaptability or versatility
If traditional ultrasonic welding is used with resin colorants, then various adapter colors can be produced, but the colorants alter the mechanical and thermal properties of the plastic making welding difficult
Solution Approach 1:
The ultrasonic welding process that is adversely affected by colorants is replaced with mechanical riveting, which is not influenced by the presence of colorants in the plastic resin
Solution Approach 2:
The problematic ultrasonic welding step that is sensitive to resin colorants is extracted from the manufacturing process and replaced with a color-independent mechanical assembly method
4Ease of manufacture
If snap-fit components are used in fiber optic adapters, then assembly can be simplified, but misalignment or improper latching occurs leading to assembly complications
Solution Approach 1:
Rivets serve as an intermediary mechanical element that provides both alignment and secure connection between the housing halves and inserted components, eliminating the misalignment issues of direct snap-fit connections
Solution Approach 2:
The rivets are pre-positioned in the housing halves before assembly, establishing precise alignment references that guide the insertion of components and ensure proper positioning before the final latching action
Data Source
AI summary
An example fiber optic adapter is provided. The fiber optic adapter includes a housing including a hollow interior, and an interior barrier wall disposed within the hollow interior. The fiber optic adapter includes an insert including a wall. At least one of the housing or the insert includes rivet extensions protruding from the interior barrier wall or the wall, respectively. At least one of the housing or the insert includes rivet alignment openings formed in the interior barrier wall or the wall, respectively. The housing is configured to receive the insert in the hollow interior such that the rivet alignment openings at least partially receive the rivet extensions, and the wall of the insert abuts the interior barrier wall of the housing.