Multi-Fiber Ferrule Protrusion for Precision Fiber Alignment
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Solution Overview
Problem
Existing multi-fiber ferrules face challenges in high-precision fiber alignment due to limitations in controlling the insertion of optical fibers, leading to the need for additional polishing steps that can be bypassed.
Innovation Solution
A multi-fiber ferrule with a deformable protrusion on the end face that surrounds microholes, allowing for precise control of fiber position and alignment, eliminating the need for extensive polishing by creating an interference fit with optical fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If optical fibers are inserted into multi-fiber ferrules with standard flat end faces, then fiber insertion can be performed, but high-precision fiber alignment is difficult to achieve and extensive polishing is required
Solution Approach 1:
The protrusion is pre-formed on the ferrule end face at the precise location where fiber alignment is needed. This preliminary structural feature eliminates the need for post-insertion polishing by providing the alignment reference before fiber insertion occurs, directly resolving the contradiction between alignment precision and polishing time
Solution Approach 2:
Instead of polishing the entire ferrule end face, only the protrusion region requires precise formation. The protrusion creates a localized high-precision alignment feature while the rest of the ferrule maintains standard manufacturing tolerances, improving fiber alignment precision without requiring extensive polishing of the whole surface
2Productivity
If the ferrule shape is modified to enable high-precision fiber insertion without polishing, then polishing steps can be eliminated, but the complexity of controlling fiber insertion increases
Solution Approach 1:
The protrusion structure performs multiple functions automatically: it provides the alignment reference, acts as the insertion stop, and guides fiber positioning all in one feature. This self-service design eliminates the need for separate polishing steps and complex external alignment mechanisms, resolving the contradiction between eliminating polishing and controlling insertion complexity
Solution Approach 2:
The protrusion features curved surfaces that naturally guide fiber insertion and provide stable contact points. The curvature enables self-alignment through geometric constraints rather than requiring complex active control systems, allowing polishing elimination while maintaining simple insertion control
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
The deformable protrusion enables precise fiber alignment, reducing polishing time and material removal, and enhances the stability of optical connections with low insertion loss.
Implementation Method 1
the protrusion is deformable when contacted by a contact target
Data Source
AI summary
The present disclosure relates to a multi-fiber optical ferrule that includes a protrusion on the ferrule end face that surrounds and encompasses ferrule microholes on the ferrule end face. The protrusion is shaped and is deformable upon contact with a contact target such that alignment of optical fibers within the ferrule can be controlled. Stated another way, the protrusion enables precision control of the fiber position relative to the ferrule end face.