Fiber Optic Connector Tuning via Ferrule Holder Keying
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Solution Overview
Problem
Existing methods for tuning fiber optic connectors to minimize optical loss due to imperfect fiber-ferrule concentricity are costly and inefficient, often requiring partial disassembly of the connector and risking alteration of the tuned position during field installation.
Innovation Solution
A method involving a ferrule holder with keying features and a manufacturing fixture that allows rotational tuning of the fiber-ferrule assembly during connector installation, maintaining the preferred angular orientation until the housing is affixed, without altering the connector's shape or dimensions, and a removable manufacturing fixture that temporarily maintains the rotational position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If non-contact methods or contact methods not involving master connector connection are used to measure fiber-ferrule concentricity, then measurement can be performed without partial disassembly, but substantial portion of ferrule outer surface must be exposed requiring removal of inner housing
Solution Approach 1:
The patent applies preliminary action by pre-positioning the ferrule within the inner housing at a controlled axial location before measurement. The ferrule is held in a specific position by the housing itself, allowing subsequent measurement without requiring housing removal. This preliminary positioning enables the measurement to be performed in the fully assembled state, resolving the contradiction between ease of manufacture and device complexity.
2Reliability
If connector is tuned in factory with inner housing covering ferrule, then optical loss is minimized, but existing methods require housing removal exposing ferrule surface
Solution Approach 1:
The patent uses preliminary action by pre-positioning the ferrule at a specific axial location within the inner housing using engagement features (such as a shoulder or stop). This predetermined positioning allows the ferrule to be accurately located before the tuning measurement is performed, enabling the entire process to occur with the housing in place. This resolves the contradiction by maintaining both high reliability through proper ferrule positioning and ease of manufacture by eliminating housing removal.
3Ease of operation
If ferrule is axially displaced to enable rotational indexing, then tuning can be performed, but end user may inadvertently alter tuned position
Solution Approach 1:
The patent applies segmentation by separating the tuning operation from the final assembled state. The ferrule is positioned and tuned while accessible during assembly, but once the inner housing is fully installed with its engagement features, the ferrule's rotational position becomes fixed and protected from user alteration. This segmentation resolves the contradiction by allowing ease of operation during manufacturing while ensuring reliability during field use.
Solution Approach 2:
The patent uses an intermediary mechanism (the inner housing with its engagement features) that mediates between the ferrule and the external environment. The housing allows the ferrule to be positioned and tuned during assembly but then protects the tuned position from inadvertent alteration by end users. This intermediary resolves the contradiction by providing both accessibility during manufacturing and stability during field operation.
Data Source
AI summary
A method for assembling a fiber optic connector utilizes a manufacturing fixture with multiple fingers that are removably affixed to an outer surface of a ferrule holder having at least one keying feature. A core position of an optical fiber relative to a ferrule retained by the ferrule holder is determined, followed by relative rotation between the ferrule holder and the manufacturing fixture to place the core position in a preferred angular orientation, and a housing is affixed over the ferrule holder the maintain the angular orientation of the core position, followed by removal of the manufacturing fixture. A ferrule holder includes at least one keying feature and at least one channel extending in a circumferential direction along an outer surface of a body structure, with a plurality of recesses extending in an axial direction along the outer surface.