Hardened Fiber Optic Connector Pre-compressed Spring Alignment
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Solution Overview
Problem
Current fiber optic connectors face challenges in ease of assembly, manufacturability, and performance, particularly due to issues like fiber core eccentricity leading to signal losses and alignment difficulties.
Innovation Solution
The development of a hardened fiber optic connector with a ferrule subassembly that includes a pre-compressed ferrule spring and a spring retainer, allowing for precise control of ferrule movement and alignment, along with a tunable connector core that can adjust the orientation of fiber core eccentricity to minimize signal losses and enhance alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spring is used to bias the ferrule assembly in a distal direction, then the ferrule can be forced proximally against the spring bias during connection, but the assembly process becomes more complex and alignment precision is reduced
Solution Approach 1:
The ferrule assembly is pre-compressed during manufacturing to establish a predetermined compression force on the spring before final assembly. This preliminary action ensures that when the connector is later assembled and connected, the ferrule is already positioned with the correct clearance and alignment, eliminating the need for complex spring biasing mechanisms during operation.
2Reliability
If fiber core eccentricity is present, then alignment between fiber cores becomes difficult and signal losses increase, but adjusting for eccentricity requires complex tuning mechanisms
Solution Approach 1:
The connector design incorporates a tunable connector core that allows adjustment of the fiber core alignment parameters. By changing the positional parameters of the fiber cores within the connector core, the system can compensate for manufacturing eccentricities and achieve optimal alignment, thereby reducing signal losses without requiring complex external tuning mechanisms.
3Ease of manufacture
If the ferrule assembly is pre-compressed, then assembly ease is improved and manufacturing is simplified, but the spring compression force must be precisely controlled
Solution Approach 1:
The ferrule assembly is pre-compressed during the manufacturing process to a predetermined degree, establishing the correct clearance and alignment before final assembly. This preliminary compression action simplifies the overall assembly process by eliminating the need for complex spring biasing mechanisms during operation, while the compression force is controlled through standardized manufacturing procedures.
4Reliability
If robust fastening arrangements are used to withstand pull loading and side loading, then connection reliability is improved, but ease of assembly is reduced
Solution Approach 1:
The connector core and ferrule assembly are pre-positioned and pre-compressed during manufacturing to establish correct alignment and clearance. This preliminary action ensures that when the robust fastening arrangements are engaged during final assembly, the components are already aligned, allowing the fastening mechanism to engage smoothly without requiring excessive force or complex alignment procedures.
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 solution improves the assembly process, reduces signal losses by aligning fiber cores effectively, and enhances the performance of fiber optic connectors by accommodating fiber buckling and adjusting core eccentricity, resulting in improved connectivity and reliability.
Implementation Method 1
A spring is used to bias the ferrule assembly in a distal direction relative to the connector housing
Data Source
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AI summary
A fiber optic connector is disclosed that includes a plug body having a plug end and a connector core that mounts within the plug body. The connector core includes a ferrule subassembly including a ferrule, a ferrule hub that attaches to the ferrule, a spring holder and a connector spring. The ferrule sub-assembly is assembled with the connector spring pre-compressed to an initial compressed state prior to mounting the connector core within the connector body. The plug body and the core are configured such that the connector spring is moved from the initial compressed state to a final compressed state when the connector core is loaded in the plug body. In certain examples, tuning features can be integrated into the connector core.