Ultrasonic Welded Fiber Optic Connector Retaining Strength Members
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Solution Overview
Problem
Existing fiber optic cable assemblies face issues with stress/strain distribution and defects during crimping of strength members, leading to potential failure and increased costs due to the use of metal components.
Innovation Solution
A fiber optic cable assembly with a weld collar and connector body that includes longitudinally-extending teeth for capturing strength members, forming a composite through ultrasonic welding, which eliminates the need for crimping and provides a robust, cost-effective solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If crimping is used to mechanically couple the fiber optic cable to the connector, then the strength members are retained, but stress/strain distribution causes susceptibility to failure and potential breaking of the plastic body
Solution Approach 1:
The patent replaces the traditional crimping mechanical system with an ultrasonic welding system. The ultrasonic welding process uses high-frequency vibration to melt and fuse the weld collar to the connector body, eliminating the need for mechanical crimping that causes stress concentration and plastic body failure. This substitution maintains strength member retention while improving reliability.
Solution Approach 2:
The patent creates a composite structure by ultrasonically welding the weld collar (containing strength members) to the connector body. This composite assembly distributes stress across the bonded interface rather than concentrating it at crimp points, preventing plastic body failure while maintaining structural integrity.
2Strength
If metal components such as metal crimp bands are used to supplement or replace plastic components, then structural strength is improved, but manufacturing cost increases
Solution Approach 1:
The patent employs a molded plastic weld collar instead of expensive metal crimp bands. The plastic weld collar is cost-effective to manufacture through molding processes and provides sufficient structural strength when ultrasonically welded to the connector body, eliminating the need for costly metal reinforcement.
Solution Approach 2:
The patent changes the material parameter from metal to plastic for the weld collar, while compensating for strength requirements through ultrasonic welding process parameters. This material substitution reduces manufacturing cost while maintaining structural integrity through the bonded composite assembly.
3Reliability
If crimping force is applied to retain strength members, then the strength members are secured, but defects such as non-uniform distribution and incorrect length are difficult to detect
Solution Approach 1:
The patent incorporates teeth on the inner surface of the weld collar before the ultrasonic welding process. These pre-formed teeth mechanically engage with and position the strength members during assembly, ensuring uniform distribution and correct positioning before welding occurs. This preliminary action prevents defects that would be difficult to detect after crimping.
4Device complexity
If direct crimping on molded plastic body is used, then the process is simple, but the resulting stress distribution makes parts susceptible to failure
Solution Approach 1:
The patent divides the connector assembly into separate functional components: the connector body and the weld collar. The weld collar is a separate molded piece that is ultrasonically welded to the connector body, creating distinct functional zones. This segmentation allows the strength members to be retained in the weld collar without directly stressing the connector body, improving reliability while maintaining simplicity.
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 ensures improved retention and uniform distribution of strength members, reducing mechanical stress on the connector body and eliminating the need for metal components, thus enhancing durability and ease of integration into automated systems.
Implementation Method 1
forming a composite including a portion of the at least one strength member and a portion of at least one of the weld collar or the connector body
Data Source
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AI summary
A fiber optic cable assembly includes a fiber optic cable including at least one strength member and a fiber optic connector including a connector body. The assembly also includes a weld collar positioned such that the at least one strength member is at least partially captured between the connector body and the weld collar. The assembly further includes a composite including a portion of the at least one strength member and a portion of at least one of the weld collar or the connector body. A method of coupling a fiber optic cable to a fiber optic connector is also provided.