Fiber Optic Connector Overmolded Lead-In Tube for Snag-Free Insertion

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Solution Overview

Problem

Fiber optic connectors face issues with optical fiber insertion due to obstructions caused by exposed ridges on lead-in tubes, ferrules, and hubs, leading to damage and improper epoxy placement.

Innovation Solution

A fiber optic connector design featuring an over-molded lead-in tube that fully encapsulates the ferrule hub, made of a flexible plastic material, with a tapered inner surface to facilitate easy insertion and prevent snagging, and includes a retention member like a barb to secure the tube.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If traditional lead-in tubes with exposed ridges are used, then structural support is provided, but optical fiber insertion is hindered and fiber damage occurs

Engineering Contradiction:

Improveoptical fiber insertionVSAvoidfiber damage from exposed ridges

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The lead-in tube is constructed from flexible plastic material that can deform to accommodate the optical fiber during insertion, eliminating the harmful effect of rigid exposed ridges while maintaining structural support functionality

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The lead-in tube is pre-formed with a tapered configuration before insertion, creating a smooth leading edge that guides the optical fiber into the connector without requiring forceful insertion that could cause damage

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If exposed ridges on lead-in tube are present, then manufacturing is simplified, but epoxy migration prevention is compromised

Engineering Contradiction:

Improvelead-in tube fabricationVSAvoidepoxy placement accuracy

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The flexible plastic lead-in tube conforms to the hub contours including ridges, creating a continuous smooth surface that prevents epoxy from migrating to undesired locations while maintaining manufacturing simplicity

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The lead-in tube provides localized smoothing coverage only where needed (over the hub ridges) while maintaining the original hub structure elsewhere, preventing epoxy migration without requiring complete redesign of the hub geometry

Inventive Principle:

Principle #3Local quality

3Stability of the object's composition

If rigid lead-in tube structure is used, then structural stability is maintained, but fiber insertion smoothness is reduced

Engineering Contradiction:

Improvelead-in tube structural stabilityVSAvoidfiber insertion smoothness

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The flexible plastic material allows the lead-in tube to provide structural stability while simultaneously conforming to the optical fiber during insertion, creating a smooth insertion path without requiring rigid precise tolerances

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS12461318B2Fiber optic connector with overmold lead-in tube

Publication Date: 2025.11.04 COMMSCOPE TECHNOLOGIES LLC

AI summary

The present disclosure relates to a fiber optic connector designed to improve the insertion of an optical fiber within the fiber optic connector. The fiber optic connector may include a lead-in tube that makes the insertion of an optical fiber easier. That is, the lead-in tube may be molded over a ferrule hub to fully encapsulate a rear end thereof such that the optical fiber does not snag or hang up during insertion.