Fiber Optic Connector Assembly Alignment Method
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Solution Overview
Problem
The existing methods for manufacturing fiber optic connector assemblies result in unpredictable and high insertion losses due to random offset between the centers of fiber cores, necessitating high precision ferrules and cables, which increase costs and complexity.
Innovation Solution
A method involving pre-adjusting the ferrule and cable fibers to specific orientations before insertion into a V-typed alignment tool, ensuring the centers of the fiber cores align vertically, minimizing the offset distance and reducing insertion loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high precision fiber optic ferrule is adopted to reduce eccentricity and diameter difference, then manufacturing precision of fiber core alignment is improved, but cost increases and difficulty to insert optical fiber into bore increases
Solution Approach 1:
The patent applies preliminary action by pre-adjusting the optical fiber to specific orientations (first predetermined orientation for ferrule fiber, second predetermined orientation for cable fiber) before insertion into the alignment tool. This pre-positioning ensures that when the fibers are inserted, their cores are already aligned along the vertical centerline of the V-typed alignment groove, eliminating the need for high precision ferrules and reducing insertion difficulty.
2Reliability
If manual adjustment of fiber core offset is performed to reduce insertion loss, then reliability of fiber optic connector is improved, but manufacturing complexity and time consumption increase
Solution Approach 1:
The patent eliminates manual adjustment complexity by pre-adjusting the fibers to specific orientations before insertion. The first fiber is adjusted to a first predetermined orientation and the second fiber to a second predetermined orientation, so that their cores automatically align when inserted into the alignment tool, achieving reliable low insertion loss without complex manual adjustment processes.
Solution Approach 2:
The alignment tool with V-typed alignment groove performs self-alignment function. When the pre-oriented fibers are inserted, the V-groove automatically positions them such that their cores align along the vertical centerline, eliminating the need for external manual adjustment mechanisms and reducing manufacturing complexity.
3Reliability
If high precision ferrule and cable are used to control fiber core offset, then insertion loss is reduced, but manufacturing cost increases
Solution Approach 1:
The patent reduces manufacturing cost by applying preliminary action - pre-adjusting the fibers to specific orientations before insertion. This approach achieves consistent low insertion loss through process control rather than relying on expensive high precision ferrules and cables, making the manufacturing process more cost-effective while maintaining reliability.
Data Source
AI summary
A method for manufacturing a fiber optic connector assembly, comprising: providing a ferrule having a first fiber and a cable having a second fiber; adjusting the ferrule to locate the first fiber at a first predetermined orientation, and adjusting the cable to locate the second fiber at a second predetermined orientation; and inserting the first fiber located at the first predetermined orientation and the second fiber located at the second predetermined orientation into a alignment tool received in a housing of a fiber optic connector. Wherein the first and second predetermined orientations are set so that a distance between a center of a fiber core of the first fiber and a center of a fiber core of the second fiber is equal to an absolute value of a difference between a distance from a center of a coat layer to the center of the fiber core of the first fiber and a distance from a center of a coat layer to the center of the fiber core of the second fiber when the first fiber located at the first predetermined orientation and the second fiber located at the second predetermined orientation are inserted into the alignment tool.