Fiber Optic Ferrule Connector with Radial Fastening and Sealing
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Solution Overview
Problem
The connection of fiber optic or rigid light guides to light sources is challenging due to vibrations during vehicle operation, leading to loose connections, damage, and limited durability against environmental factors like water and moisture, especially in mass production scenarios where assembly is complicated and error-prone.
Innovation Solution
A two-step fastening process using a connecting element with radially biased fastening portions and a fixing element to apply increasing retention forces, ensuring the ferrule and light guide are securely positioned without requiring manual holding, and a sealing element for protection against environmental loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rubber annularly surrounding the fiber optic light guide is pressed radially inwardly by screwing a sleeve nut onto the screw, then the axial position of the ferrule is determined, but it is not possible to check whether the ferrule actually has the correct distance from the light source
Solution Approach 1:
The connecting element is designed with an integrated measurement mark that automatically indicates when the correct axial position is achieved during assembly. The measurement mark is visible through a transparent or translucent portion of the connecting element, allowing the assembly operator to self-verify the correct position without additional checking tools or procedures.
2Manufacturing precision
If the assembly operator has to grasp permanently the fiber optic light guide with one hand, then the fiber optic light guide is pressed toward the light source during the entire assembly process, but the assembly process is complicated because often there is only a very limited installation space available and the assembly operator cannot move away from the connection
Solution Approach 1:
A positioning element with a positioning projection is introduced as an intermediary component. The positioning projection engages with a corresponding recess in the light source, automatically maintaining the correct axial distance and positioning the fiber optic light guide in the correct position during assembly. This eliminates the need for the assembly operator to manually hold and press the light guide, freeing both hands for tool manipulation.
3Reliability
If screws are used to secure the fiber optic light guide and ferrule, then the connection can withstand vibrations during vehicle operation, but the axial position of the ferrule cannot be clearly defined by the screw
Solution Approach 1:
The connecting element combines multiple functions into a single integrated component: it provides the screw connection for vibration resistance, incorporates the measurement mark for position verification, and integrates the positioning element for axial distance definition. This unified design ensures both connection stability and manufacturing precision without requiring separate components.
4Strength
If the fiber optic light guide is pressed toward the light source during assembly, then the connection is secured, but there is a danger that the assembly operator damages the glass fibers by the pressing process because they are only in a small degree resistant to loads exerted by pressure, bending or torsion
Solution Approach 1:
The positioning element with the positioning projection is installed beforehand to establish the correct axial position and pre-load the fiber optic light guide in the proper direction. This preliminary positioning ensures that subsequent tightening of the screw connection does not require excessive pressing forces, thereby preventing damage to the glass fibers while still achieving the necessary connection strength.
Data Source
AI summary
A system and an apparatus for connecting a fiber optic or rigid light guide to a light source are provided. The fiber optic or rigid light guide has one end connected to a ferrule with a contact surface. The system includes a connecting element connectable to the light source, into which the ferrule can be inserted. The connecting element has a number of radially movable fastening portions, wherein the fixing portions are radially biased and cooperate with the contact surface, when the ferrule is inserted into the connecting element, whereby a first retention force is applied to the contact surface, and a fixing element is positioned in such a way that it cooperates with the fastening portions so that a second retention force, which is greater than the first retention force, is applied to the contact surface.