Optical Fiber Reshaping for Ferrule Eccentricity Correction

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Solution Overview

Problem

The existing methods for assembling optical fiber connectors are costly due to the use of bonding agents and complex processing steps, and they fail to effectively address core-to-ferrule eccentricity errors, which affect the alignment and insertion loss of optical fibers.

Innovation Solution

The use of laser treatment to modify the optical fiber's surface by creating protrusions that engage with the ferrule bore, providing a secure interference fit without adhesives and correcting core-to-ferrule eccentricity errors, thereby simplifying the assembly process and reducing material costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If bonding agent is used to secure optical fiber within ferrule, then fiber locking is achieved, but manufacturing cost and process complexity increase

Engineering Contradiction:

Improvefiber locking securityVSAvoidassembly process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention extracts and removes the bonding agent from the fiber securing system, replacing it with a mechanical interference fit mechanism. The protrusions on the fiber outer cladding engage directly with the ferrule bore, eliminating the need for adhesive materials and simplifying the assembly process while maintaining secure fiber locking.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention replaces the chemical bonding mechanism with a mechanical interference fit system. The protrusions create physical engagement between the fiber and ferrule through geometric interlocking, substituting the chemical adhesion of bonding agents with a purely mechanical locking mechanism that provides equivalent or superior security.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If bonding agent is used to secure optical fiber within ferrule, then fiber locking is achieved, but material cost increases

Engineering Contradiction:

Improvefiber locking securityVSAvoidbonding agent material cost

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of manufacture

If conventional fiber insertion method is used, then fiber placement is achieved, but core-to-ferrule eccentricity error remains

Engineering Contradiction:

Improvefiber insertion simplicityVSAvoidcore-to-ferrule alignment precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The invention introduces asymmetric protrusions on the fiber outer cladding that engage with the ferrule bore in a specific orientation. This asymmetric geometry provides mechanical feedback during insertion, guiding the fiber into correct alignment and compensating for core-to-ferrule eccentricity errors that would otherwise occur with conventional symmetric insertion methods.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The protrusions provide tactile and mechanical feedback during the fiber insertion process, allowing the fiber to self-align with the ferrule bore. This feedback mechanism compensates for manufacturing tolerances and eccentricity errors by guiding the fiber into the correct position through the interference fit engagement.

Inventive Principle:

Principle #23Feedback

4Reliability

If laser treatment is applied to create protrusions, then fiber locking and alignment are improved, but energy consumption increases

Engineering Contradiction:

Improvefiber locking securityVSAvoidlaser treatment energy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The invention uses laser treatment to modify the physical parameters of the fiber outer cladding surface, creating protrusions through controlled ablation or melting. By adjusting laser parameters such as power density, pulse duration, and scan speed, the process efficiently creates the required geometric features with minimal energy consumption, transforming the fiber surface properties to enable mechanical engagement.

Inventive Principle:

Principle #35Parameter changes

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

This method achieves a secure optical fiber locking mechanism with reduced insertion losses and improved alignment, minimizing the need for adhesives and simplifying the assembly process while effectively addressing core-to-ferrule eccentricity issues.

Implementation Method 1

applying a laser treatment onto the optical fiber to create at least one protrusion along an outer surface of the optical fiber

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

the ferrule is heated to expand the ferrule and ferrule bore

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 3

the ferrule cools to room temperature, thereby, contracting the ferrule, and locking the optical fiber within the ferule

Methodology Applied

Scientific EffectThermal contraction: Thermal Contraction

Data Source

PatentUS20240111101A1Methods of optical fiber reshaping for direct locking optical fibers and correcting core-to-ferrule eccentricity errors

Publication Date: 2024.04.04 CORNING RES & DEV CORP

AI summary

The present disclosure relates to laser treatment of an optical fiber to secure the optical fiber within a ferrule bore. In particular, the laser treatment modifies the physical structure of the optical fiber to aid in securing the optical fiber within the ferrule bore and to correct core-to-ferrule eccentricity errors.