Fiber Optic Connector Retention Assembly Welding
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Solution Overview
Problem
Conventional fiber optic connectors have weak connections due to crimping onto Kevlar strengthening members, require specialized tools, and can result in unreliable connections, especially in cables with less Kevlar, such as Miniflex fiber cables.
Innovation Solution
A fiber optic connector retention assembly that secures the connector body to the cable jacket using a metallic split ring, which is welded to the connector body, eliminating the need for crimping and providing increased connection strength without requiring a crimping tool, and is designed to fit into an annular groove in the cable jacket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional crimping methods are used to attach connectors to Kevlar strengthening members, then the connector can be secured to the cable, but the connection becomes weak and easy to bend
Solution Approach 1:
The patent replaces the mechanical crimping system with a welding system. The connector body is welded directly to the cable jacket using arc welding or laser welding, eliminating the need for crimping tools and Kevlar strengthening members. This substitution provides a stronger, more reliable weld connection that resists bending and pulling forces better than conventional crimping.
Solution Approach 2:
The patent uses composite construction by welding the metallic connector body directly to the cable jacket, creating a composite structure that combines the strength of metal welding with the flexibility of the cable jacket. This composite approach eliminates the weak interface between crimped connectors and Kevlar, providing superior connection strength and reliability.
2Ease of manufacture
If crimping tools are used to secure connectors, then the connector can be attached to the cable, but specialized tools are required and installer error can lead to poor connections
Solution Approach 1:
The patent replaces the mechanical crimping operation with a welding operation that can be performed with simpler, more common equipment. Arc welding or laser welding equipment is more widely available and easier to operate than specialized crimping tools, improving both ease of manufacture and installation convenience.
Solution Approach 2:
The welding process is self-regulating to a degree, where the heat-affected zone and penetration depth are controlled by the welding parameters rather than requiring precise manual adjustment of crimping force. This reduces installer error and makes the process more forgiving, improving ease of operation.
3Strength
If double crimping is used to retain the connector, then the connector can be secured to the cable, but the process requires crushing the cable and increases complexity
Solution Approach 1:
The patent replaces the complex double crimping mechanical process with a single welding operation. The welding process creates a strong bond in one step without requiring multiple crimping operations or cable crushing, thereby reducing device complexity while maintaining or improving connection strength.
Solution Approach 2:
The connector body is positioned and aligned with the cable jacket before welding, ensuring proper placement in a single preparatory step. This preliminary positioning eliminates the need for multiple adjustment and crimping operations, simplifying the overall process while ensuring strong connection.
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 solution provides a secure, crimping-free connection that resists pull forces and maintains reliability across various fiber optic cable types, enhancing the strength and ease of installation by eliminating the need for specialized tools and potential installer errors.
Implementation Method 1
the split ring is configured to expand radially outward when slid over non-grooved portions of the fiber optic cable and to retract radially inward to a rest configuration when positioned in the annular groove in the jacket of the fiber optic cable
Implementation Method 2
The split ring and the rear sleeve portion are welded together about a periphery of the engaged surface
Data Source
AI summary
A fiber optic cable connector configured to be securely coupled with a cable jacket without crimping includes a connector body including a rear sleeve portion configured to receive a jacket of a fiber optic cable, a ferrule holder configured to be slidingly seated in a forward end of the connector body, a ferrule configured to be seated in the ferrule holder and to terminate an optical fiber, and a retention member having an inner diameter sized to fit into an annular groove in the jacket of the fiber optic cable and an outer diameter sized to extend radially outward of an outer surface of the jacket such that the retention member is configured to engage a surface of the rear sleeve portion of the connector body when the retention member is seated in the annular groove in the jacket so as to increase connection strength between the connector body and the jacket and to resist pull force on the fiber optic cable without crimping the connector body to the jacket.