Lensed Fiber Optic Ferrule With Fixed-Core Mold Ejection

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Solution Overview

Problem

Current molding processes for lensed fiber optic ferrules require multiple moving parts, leading to uncertainty in lens core positioning and the potential for undesirable undercuts during ejection, which affects loss performance.

Innovation Solution

A fixed core design for the lensed ferrule is implemented, where only the guide pin holes or alignment features move during ejection, ensuring the ferrule is ejected in a direction parallel to the vertical axes without moving the lens core, eliminating undercuts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If multiple moving parts are used in the molding process, then the ferrule can be ejected from the mold, but the lens core positioning becomes uncertain and undercuts may occur

Engineering Contradiction:

Improveejection processVSAvoidlens core positioning

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent inverts the traditional molding approach by making the lens core fixed and the ferrule body movable. Instead of moving the lens core to eject the ferrule, the ferrule is designed with an angled front face that allows ejection while the lens core remains stationary, thereby eliminating positioning uncertainty and undercut issues

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The ferrule front face is designed with an angled configuration rather than a perpendicular one. This asymmetric design creates a sloped surface that facilitates ferrule ejection from the mold without requiring the lens core to move, thus maintaining precise lens positioning while enabling successful ejection

Inventive Principle:

Principle #4Asymmetry

2Productivity

If the lens core moves during ejection, then the ferrule can be released from the mold, but uncertainty in lens positioning and potential undercuts occur

Engineering Contradiction:

Improveejection efficiencyVSAvoidlens positioning control

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent reverses the traditional approach by keeping the lens core fixed and allowing the ferrule to be ejected through its angled front face design. This inversion maintains reliable lens positioning control while achieving efficient ejection without requiring lens core movement

Inventive Principle:

Principle #13The other way round (Inversion)

3Device complexity

If the front face is perpendicular to the longitudinal axis, then the molding process is simpler, but undercuts occur during ejection

Engineering Contradiction:

Improvemolding processVSAvoidejection process

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The patent applies asymmetry by designing the front face at an angle rather than perpendicular to the longitudinal axis. This angled configuration eliminates undercuts during ejection while maintaining reasonable molding process complexity through the use of a fixed lens core and simplified mold design

Inventive Principle:

Principle #4Asymmetry

Data Source

PatentUS12546953B2Lensed fiber optic ferrule with simplified molding

Publication Date: 2026.02.10 US CONEC LTD

AI summary

A fiber optic ferrule has a main body with a top surface and a bottom surface and extends between a front end and a back end. The front face includes a recessed portion with a plurality of optical lenses. The front face is configured to allow for the plurality of lenses to be on an angle relative to the front face and the fiber optic ferrule will have not any undercuts and allow the fiber optic ferrule to be ejected from a mold without engaging any portions of the mold.