Multi-core Ferrule Curvature for Single-Mode Fiber Alignment
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Solution Overview
Problem
Current optical fiber connection structures, particularly in multi/single-core connections, face challenges in achieving physical contact (PC) connections to minimize optical loss, which is difficult to ensure due to variations in optical fiber bundle protrusion and requires high precision and increased production costs.
Innovation Solution
A multi-core ferrule with a convex spherical end surface and a smaller through hole is designed to align and abut with a single-core ferrule, ensuring physical contact and minimizing optical loss, while maintaining a low production cost by using zirconia materials and specific curvature radii for the end surfaces and through holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a convex spherical end surface with small curvature radius is used for multi-core ferrule to ensure physical contact connection, then optical loss is minimized, but manufacturing precision requirements increase and production cost rises
Solution Approach 1:
The patent changes the curvature radius parameter of the multi-core ferrule end surface to a specific range (18.3 mm to 38.7 mm) that is larger than conventional small curvature radii. This parameter adjustment maintains physical contact connection and minimizes optical loss while reducing the stringency of manufacturing precision requirements, thereby lowering production costs.
Solution Approach 2:
The patent introduces an intermediary mechanism where the multi-core ferrule end surface with convex spherical shape in a specific curvature range acts as a mediator between the optical fiber bundle and the single-core ferrule. This intermediary structure ensures uniform protrusion of optical fibers and achieves physical contact connection without requiring extremely high manufacturing precision.
2Reliability
If high precision is required to uniformly protrude optical fibers in multi/single-core connection, then physical contact connection is achieved, but production cost increases
Solution Approach 1:
By changing the curvature radius parameter to a larger range (18.3 mm to 38.7 mm), the patent reduces the difficulty of manufacturing while maintaining reliable physical contact connection. This parameter optimization allows for easier production without compromising connection reliability.
Solution Approach 2:
The patent employs a convex spherical end surface with a specifically optimized curvature radius range. This spherical geometry with moderate curvature facilitates uniform protrusion of optical fibers during the connection process, achieving reliable physical contact connection while simplifying manufacturing requirements and reducing production costs.
3Manufacturing precision
If the through hole diameter is reduced for better alignment, then connection precision is improved, but manufacturing complexity increases
Solution Approach 1:
The patent optimizes the through hole diameter parameter to a specific range that provides sufficient alignment precision for multi-core to single-core connection. This parameter optimization achieves good alignment without requiring overly complex through hole structures or additional alignment mechanisms.
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 solution effectively minimizes optical loss and ensures a physical contact connection at a lower cost by using a multi-core ferrule with a convex spherical end surface and a smaller through hole, aligning with a single-core ferrule, achieving high light transmission and prolonged output stability.
Implementation Method 1
a ferrule holding an optical fiber is finished to have a convex spherical end surface with a curvature radius of 15 mm to 25 mm, and two ferrules, each holding the optical fiber, are pressed against each other, thereby elastically deforming their end surfaces. Owing to this, there is no gap formed between the end surfaces, thus ensuring the PC connection.
Implementation Method 2
The second through hole penetrates the center of the second end surface and has a smaller diameter than the first through hole. The optical fiber bundle is inserted into the second through hole such that an end surface of the optical fiber bundle coincides with the second end surface.
Data Source
AI summary
An optical fiber connection structure includes a single-core plug holding a single-core ferrule, a multi-core plug holding a multi-core ferrule, and an adaptor having a tubular sleeve. The single-core ferrule made of zirconia (ZrO2) has a cylindrical shape and is held in a holder made of stainless steel (SUS). The single-core ferrule has a convex end surface whose curvature radius R1 is at least 50 mm. The multi-core ferrule made of zirconia (ZrO2) has a cylindrical shape and is held in a holder made of stainless steel (SUS). The multi-core ferrule has a convex end surface whose curvature radius R2 is at least 18.3 mm and at most 38.7 mm. When the first and second plugs are attached to the adaptor, the singe-core ferrule and the multi-core ferrule are respectively inserted from the opposite ends into the sleeve, and both of the end surfaces of the ferrules are pressed against each other.