Fiber Optic Mechanical Splice for Military Aircraft
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Solution Overview
Problem
Current fiber optic mechanical splices are not suitable for use in environments sensitive to heat, such as military aircraft, and fail to meet the Aircraft Mechanical Splice Military Specification (MIL-PRF 24623/7), requiring a more robust and reliable splicing solution that can handle optical fibers with one or two strength members.
Innovation Solution
A fiber optic mechanical splice comprising a capillary tube made of terafluoroethylene and perfluoromethyl vinyl ether copolymer, metallic bridging flanges from pre-treated stainless steel, crimping tubes from anodized aluminum alloy, and a protective structure sealed with tri-valent chromium and Teflon, along with polyurethane tape for environmental sealing, allowing for assembly by technicians and meeting the MIL-PRF-24623/7 qualification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fusion splicing is used to join optical fibers, then the splice strength and optical transmission are improved, but the device generates heat which is harmful in sensitive environments
Solution Approach 1:
The patent replaces the thermal fusion process with a mechanical splicing system. Two optical fiber cables are mechanically aligned and held together by a capillary tube assembly with bridging flanges, eliminating the need for heat generation while achieving sufficient splice strength for the application.
2Productivity
If mechanical splicing with resin is used to join optical fibers, then the installation speed is improved, but the optical loss increases and robustness decreases
Solution Approach 1:
The patent removes the resin or clear index-matching material from the splicing system. Instead of using resin to enhance light transmission, the invention relies on direct mechanical contact and alignment of the optical fiber ends within the capillary tube, eliminating the intermediate material that caused optical loss and reliability issues.
3Ease of operation
If existing mechanical splice designs are used, then the ease of installation is improved, but the adaptability to different cable configurations (one or two strength members) is limited
Solution Approach 1:
The patent designs the capillary tube assembly with bridging flanges that can accommodate optical fiber cables with either one or two strength members. The universal design allows the same splicing mechanism to handle different cable configurations, increasing adaptability while maintaining ease of installation through a standardized procedure.
Data Source
AI summary
A fiber optic mechanical splice for splicing input and output optical fiber. The splice includes a capillary tube for enclosing fiber ends of the input and output optical fiber cables, two metallic cable-splice bridging flanges for insertion onto the input and output optical fiber cable jackets, a first metallic crimping tube, a second metallic crimping tube, a first protection tube, a second protection tube, and polyurethane tape. The fibers extending from the input and output optical fibers can be frustoconically inserted into a corresponding bridging flange. The crimping tubes enclose corresponding cable ends and bridging flanges. The first protection tube encloses the crimping tubes, while the second protection tube encloses the first protection tube and the tape is disposed over the second protection tube, the bridging flanges, and the crimping tubes.