Fiber Optic Ferrule With Deformable Conical Distal End
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Solution Overview
Problem
Current fiber optic connectors require extensive end polishing and mechanical support, leading to inefficiencies in signal transmission and potential loosening of the optical fiber after assembly, due to the need for significant removal and re-shaping of the ferrule and optical fiber ends.
Innovation Solution
A ferrule design with a broad non-flat conical distal end and outwardly extending rings that deform to securely engage the optical fiber, allowing for close proximity cleavage and minimal polishing, reducing the need for extensive end preparation and enhancing retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional ferrule designs are used with mechanical crimping or swaging around the optical fiber, then the optical fiber can be mechanically secured, but extensive end polishing is required afterward to remove projecting fiber and reshape the ferrule end
Solution Approach 1:
The ferrule distal end is pre-formed with a conical configuration and an outwardly extending ring at the desired final shape before assembly. When the ferrule is crimped or swaged around the optical fiber, the ring deforms to secure the fiber while the pre-formed conical end requires minimal polishing, eliminating the need to remove significant material after assembly.
Solution Approach 2:
The ferrule distal end is divided into functional zones: a conical portion for alignment and a distinct outwardly extending ring for mechanical engagement. This segmentation allows each zone to perform its specific function independently, with the ring providing secure fiber retention while the conical portion maintains optical alignment with minimal polishing required.
2Manufacturing precision
If significant material is removed and re-shaped during polishing, then proper signal transmission is achieved, but the optical fiber may loosen after assembly
Solution Approach 1:
The outwardly extending ring is pre-formed at the ferrule distal end before assembly. During crimping or swaging, this ring deforms to create strong frictional engagement with the optical fiber, securing it firmly. This preliminary formation of the retention structure eliminates the need for extensive post-assembly polishing that would otherwise compromise fiber retention.
Solution Approach 2:
The ferrule distal end geometry is changed from a traditional cylindrical shape to one featuring a conical configuration with an outwardly extending ring. This parameter change in shape allows the ring to deform during mechanical engagement, creating enhanced frictional forces that secure the optical fiber while maintaining the precision needed for signal transmission.
3Strength
If conventional ferrule designs are used, then mechanical support is provided, but extensive polishing is required to achieve proper signal transmission
Solution Approach 1:
The ferrule is manufactured with a pre-formed conical distal end and an outwardly extending ring at the desired final configuration. This preliminary shaping means that during assembly and crimping, the structure maintains its precision geometry requiring minimal polishing, significantly simplifying the manufacturing process while maintaining strong mechanical support.
Solution Approach 2:
The ferrule distal end employs a conical configuration with a curved outwardly extending ring instead of a traditional flat or cylindrical end. This curved geometry is pre-formed to the precise angles needed for optical alignment, reducing the polishing complexity while maintaining the mechanical strength required for reliable fiber engagement.
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
The ferrule design significantly reduces the need for post-assembly polishing, enhances optical fiber retention, and minimizes loosening, thereby improving signal transmission efficiency and reducing costs.
Implementation Method 1
The distal end portion is mechanically inwardly deformable to frictionally engage the optical fiber within the bore
Implementation Method 2
the distal end being either conically shaped having a cone angle such that the distal end is also deformed into a substantially planar surface
Data Source
AI summary
A ferrule connectable to a fiber optic cable having an exposed portion of a length of optical fiber extending from a protective buffer. The ferrule includes a cylindrical body including an optical fiber bore coaxial with the body which extends longitudinally from a proximal end of the body through a distal end portion thereof sized to slidably receive the optical fiber therethrough. The distal end portion is mechanically deformable to frictionally engage the optical fiber within the bore, the distal end being either conically shaped or including an outwardly extending ring resulting in the distal end being a substantially planar surface, whereby a projecting length of the optical fiber extending beyond the distal end may be cleaved in very close proximity to the distal end.