Multi-Core Optical Connector Alignment for Low Splicing Loss
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Solution Overview
Problem
Existing methods for manufacturing optical connectors fail to address the issue of high splicing loss when multi-core optical fibers are connected, due to deviations in the position of cores on the end surfaces before and after polishing, which are not adequately controlled.
Innovation Solution
A method involving the preparation of multi-core optical fibers with controlled deviation angles in the circumferential direction, where the angle between the end surface and a cross-section is maintained at 0.9° or less, achieved through polishing and alignment processes, ensuring precise core alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ferrules are held in positioning holes during ultrasonic cutting, then cutting precision is improved, but the positioning holes may be damaged by the cutting blade
Solution Approach 1:
A support plate is introduced as an intermediary component between the positioning holes and the ultrasonic cutting blade. The support plate receives the cutting force and transmits it to the ferrule through its bottom surface, preventing direct contact between the blade and positioning holes while maintaining cutting precision and preserving hole integrity.
2Manufacturing precision
If multiple separate fixtures are used to hold ferrules and position cutting blades, then positioning accuracy is improved, but device complexity increases
Solution Approach 1:
Multiple functions previously requiring separate fixtures are merged into a single support plate. The support plate simultaneously provides positioning surfaces for ferrules, guides for cutting blades, and structural support for the cutting operation, thereby reducing device complexity while maintaining positioning accuracy.
3Adaptability or versatility
If manual assembly steps are used for connector components, then flexibility is improved, but production efficiency decreases
Solution Approach 1:
The assembly process is segmented into distinct modular steps: first assembling the housing assembly with positioning features, then separately preparing ferrules with positioning holes, and finally combining them in a standardized ultrasonic welding process. This segmentation allows for flexible preparation of individual components while enabling high-efficiency automated assembly through the standardized final joining step.
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 enables low splicing loss by maintaining precise core alignment, allowing for efficient connection of multi-core optical fibers using connectors.
Implementation Method 1
an ultrasonic blade is used to melt both the first ferrule and the housing assembly at the first location
Implementation Method 2
the ultrasonic blade is used to melt both the first ferrule and the housing assembly
Data Source
Figure 1
Figure 2
Figure 3(A)~33(D)
AI summary
There is provided a method of manufacturing an optical connector, including: preparing a multi-core optical fiber including a glass fiber and a resin coating that covers the glass fiber; inserting the glass fiber exposed from the resin coating into the ferrule at one end of the multi-core optical fiber such that the glass fiber protrudes from an end surface of a ferrule by a length A; rotating and aligning the multi-core optical fiber with respect to the ferrule; fixing the multi-core optical fiber to the ferrule; and polishing one end of the protruding glass fiber and the end surface of the ferrule so as to scrap off a tip end of the ferrule by a length B. A deviation angle in the circumferential direction between a first initial end surface of the one end of the prepared glass fiber and a cross section of the glass fiber separated from the initial end surface by a length A + B mm is equal to or less than 0.9°.