Multi-Part Optical Fiber Connector Assembly
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Solution Overview
Problem
Existing optical fiber connectors face challenges with precise and efficient assembly, as they require large bores for insertion, leading to inaccuracies and increased handling difficulties, especially when dealing with multiple fibers, resulting in high manufacturing costs and inefficiencies.
Innovation Solution
A multi-part connector design featuring guide pieces with stops and counterparts allows for precise positioning of optical fibers by forming a defined guide volume, eliminating the need for drilling and enabling secure holding of individual or multiple fibers without additional aids, using transparent plastic ferrule half-shells that can be quickly assembled with UV-curable adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a simple sleeve ferrule with a large bore is used to facilitate fiber insertion, then ease of operation is improved, but manufacturing precision deteriorates due to positioning inaccuracies
Solution Approach 1:
The ferrule is divided into two separate half-shells that are assembled together. This segmentation allows the fiber to be positioned and fixed between the two halves, providing precise positioning through the assembly interface while maintaining ease of insertion through the combined structure
Solution Approach 2:
A guide piece with a guide groove and stop is introduced as an intermediary component between the fiber and the ferrule structure. The guide piece precisely positions the fiber in the longitudinal direction using the stop, while the guide groove accommodates the fiber, enabling accurate positioning without requiring a precisely fitted bore
2Ease of operation
If a large bore is used for fiber insertion, then ease of operation is improved, but device complexity increases due to the need for additional mechanical guides
Solution Approach 1:
The positioning function previously requiring separate mechanical guides is merged into the ferrule structure itself. The two half-shells and guide piece together provide both the insertion pathway and the positioning mechanism, eliminating the need for additional external guides
Solution Approach 2:
The ferrule structure is designed to perform multiple functions: the half-shells provide structural support and protection, the guide piece provides positioning, and the assembled structure facilitates both insertion and precise alignment. This multi-functionality reduces the need for separate components
3Device complexity
If adhesive fixation in a simple sleeve is used, then device complexity is reduced, but manufacturing precision deteriorates due to positioning inaccuracies
Solution Approach 1:
Dividing the ferrule into two half-shells creates a precise assembly interface that defines the fiber position. The fiber is fixed between the two halves, and the precision comes from the mating surfaces of the half-shells rather than from adhesive positioning in a single sleeve
Solution Approach 2:
The guide piece with its stop and groove structure provides self-positioning for the fiber. When the half-shells are assembled, the guide piece automatically positions the fiber in the correct location without requiring external alignment tools or complex adhesive application 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 design simplifies and accelerates the assembly process, reduces inaccuracies, and lowers costs by providing precise and defined positioning of optical fibers relative to the connector's geometry, enhancing the optical coupling efficiency and reducing the risk of fiber damage during attachment.
Implementation Method 1
using transparent plastic ferrule half-shells that can be quickly assembled with UV-curable adhesives
Data Source
Figure 1~3
Figure 4~5
Figure 6~8
AI summary
The connection part (10) has a casing body in which end regions (46) of optical fibers (40) are accommodated. The body is formed in multi-part. The body has a guiding piece (20) that is provided with a stop unit, and a counter piece (60). The end regions of the fibers are fixed in defined position in an assembled condition of the body with the counter piece relative to the guiding piece. The guiding piece and the counter piece are made of plastic e.g. methyl methacrylate acrylonitrile butadiene styrene.