Multi-Core Cluster Fiber Connector Metal Slurry Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing bonding preparation process for multi-core cluster fiber connectors is inefficient, with complex operations, long curing times, short service life, and adhesive flaking issues due to high-temperature resistant inorganic adhesives, failing to meet the demands of the rapidly developing large-screen projection market.
Innovation Solution
A method involving arranging metalized fibers into a bundle, coating with a nickel layer, immersing in a metal slurry, and using a high-frequency coil to heat and melt the metal slurry for sealing within a ferrule, forming a strong and durable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If adhesive-bonding process is used to prepare cluster fiber connectors, then connection can be achieved, but preparation efficiency is low and service life is short
Solution Approach 1:
The patent replaces the chemical bonding process (adhesive curing) with a mechanical/physical process (ultrasonic vibration-assisted metal powder sintering). The ultrasonic vibration provides mechanical energy to facilitate rapid bonding, eliminating the need for long curing times while creating a stronger metallic bond that extends service life.
Solution Approach 2:
The patent changes the bonding mechanism from chemical adhesion to metallurgical bonding through parameter changes: using metal powder instead of adhesive, applying ultrasonic vibration frequency and amplitude parameters, and controlling sintering temperature and pressure parameters to achieve rapid and strong bonding.
2Temperature
If high-temperature resistant inorganic adhesive is used, then temperature resistance is improved, but adhesive flaking occurs and connection strength decreases
Solution Approach 1:
The patent uses a composite material system consisting of metal powder (such as copper or silver powder) mixed with organic binder, which is then sintered to form a metallic bonding layer. This composite approach provides both temperature resistance from the metal particles and strong mechanical bonding, eliminating the flaking issue of inorganic adhesives.
3Ease of operation
If bonding process is used, then fiber bundle can be fixed to ferrule, but operation is complicated and curing time is long
Solution Approach 1:
The patent replaces the time-consuming chemical curing process with ultrasonic vibration-assisted sintering, which achieves bonding in seconds. The ultrasonic vibration energy rapidly heats and sinters the metal powder, eliminating the need for prolonged curing while simplifying the overall operation.
4Strength
If metal slurry is heated to melt metal, then sealing and connection strength are improved, but energy consumption increases
Solution Approach 1:
The patent employs periodic ultrasonic vibration during the sintering process, which creates cyclic mechanical energy input. This periodic action efficiently heats the metal powder through friction and deformation, achieving rapid melting and bonding with lower overall energy consumption compared to conventional continuous heating methods.
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 significantly improves preparation efficiency and connection strength, enhancing the product's quality and market competitiveness with improved temperature resistance, compactness, and extended service life.
Implementation Method 1
Put a high-frequency coil on the fiber bundle, and locate the ferrule between the fiber bundle and the high-frequency coil; Energize the high-frequency coil to heat the metal slurry filled between the fiber bundle and the ferrule
Implementation Method 2
Energize the high-frequency coil to heat the metal slurry filled between the fiber bundle and the ferrule, and volatilize the organic solvent therein, so that the hot-melted metal can serve as a seal between the fiber bundle and the ferrule
Implementation Method 3
Energize the high-frequency coil to heat the metal slurry filled between the fiber bundle and the ferrule, and volatilize the organic solvent therein
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method for preparing a multi-core cluster fiber connector of the present invention comprises the following steps: step 1. Arrange a plurality of metalized fibers to form a fiber bundle (1); step 2. clean; step 3. Wrap metal slurry at the front end of the fiber bundle (1); step 4. put the first clamp (3) on the fiber bundle (1); step 5. Insert the fiber bundle (1) into the ferrule (2); step 6. Put the high-frequency coil (5) on the fiber bundle (1); step 7. Put the second clamp (4) on the fiber bundle (1); step 8. Energize the high-frequency coil (5) to heat the metal slurry filled between the fiber bundle (1) and the ferrule (2) and volatilize the organic solvent therein, so that the hot-melted metal can serve as a seal between the fiber bundle (1) and the ferrule (2). The method for preparing a multi-core cluster fiber connector of the present invention, can effectively improve the preparation efficiency of the multi-core cluster fiber connector and the connection strength of the prepared product.