Integrated Fiber-Ferrule Reducing Core Eccentricity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional fiber optic connectors face challenges in reducing insertion loss due to core to ferrule eccentricity, which is influenced by the concentricity of the ferrule micro-hole, optical fiber, and cladding layer, leading to increased manufacturing complexity and cost.
Innovation Solution
The integration of a core surrounded by a cladding layer with a lower refractive index, where the cladding layer's outer diameter is significantly larger than the core, forming an integrated fiber-ferrule that eliminates variability in core to ferrule eccentricity through direct contact without adhesives, and a fusion splice joint is used to connect the optical fiber and integrated fiber-ferrule.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional fiber optic connectors use separate ferrule and fiber components with adhesives, then assembly flexibility is improved, but core to ferrule eccentricity increases and manufacturing complexity increases
Solution Approach 1:
The patent merges the fiber and ferrule into a single integrated fiber-ferrule component where the cladding layer serves as the ferrule structure. This eliminates the separate ferrule and adhesive components, reducing core to ferrule eccentricity by ensuring perfect concentricity between the core and ferrule structure, while simplifying manufacturing processes.
Solution Approach 2:
The integrated fiber-ferrule uses composite material structure where the cladding layer (with different refractive index) forms the ferrule portion. This composite structure maintains the optical properties of the fiber while providing the mechanical support of a ferrule, eliminating the need for separate ceramic ferrule components and adhesives.
2Manufacturing precision
If conventional fiber optic connectors use precision ceramic ferrules with tight tolerances, then alignment precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent combines the fiber and ferrule manufacturing processes into a single integrated production line. The integrated fiber-ferrule is manufactured as one piece using existing fiber drawing equipment, eliminating the need for separate precision ceramic ferrule manufacturing and assembly processes, thereby reducing manufacturing cost while maintaining alignment precision.
Solution Approach 2:
The cladding layer itself serves dual functions: as the optical waveguide structure and as the ferrule providing mechanical support and alignment features. This self-service approach eliminates the need for separate ferrule components and complex assembly processes, reducing manufacturing complexity and cost.
3Ease of operation
If conventional fiber optic connectors use multiple components with adhesives, then assembly ease is improved, but insertion loss increases
Solution Approach 1:
The patent merges the fiber and ferrule into a single integrated component, eliminating adhesive interfaces that cause insertion loss. The direct integration ensures perfect optical coupling between the core and ferrule structure, minimizing reflection and scattering losses while simplifying the connector assembly.
Solution Approach 2:
The patent extracts and eliminates the adhesive layer from the connector structure. By removing the adhesive interface between fiber and ferrule, the invention eliminates the source of additional insertion loss that occurs at adhesive boundaries, while still providing secure mechanical attachment through the integrated structure.
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 approach reduces core to ferrule eccentricity and insertion loss, simplifies manufacturing, and lowers costs by eliminating the need for precise ferrule and fiber matching, while maintaining compatibility with existing connectors.
Implementation Method 1
a cladding layer that peripherally surrounds the core and that has a lower index of refraction than the optically transmissive material of the core
Implementation Method 2
a fusion splice joint joining a front end of an optical fiber core and a rear end of a core of the integrated fiber-ferrule
Data Source
AI summary
An integrated fiber-ferrule useable as an optical coupling element includes a core directly contacting a cladding layer that has a lower index of refraction than that of the core, without an intervening adhesive. The cladding layer outer diameter is at least 100 times greater than that of the core, and matches an outer diameter of a standard ferrule. The integrated fiber-ferrule may be produced by drawing a glass preform into a cane, cutting the cane into sections, and shaping end faces of the cut sections (e.g., using a laser). To form a fiber optic assembly, a front end of an optical fiber core may be fusion spliced to a rear end of the core of the integrated fiber-ferrule. Use of an integrated fiber-ferrule permits reduction of core to fiber eccentricity, and reduction of connector insertion losses.