Multifiber Ferrule Bumper Height Tolerance via Jig Grinding

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Solution Overview

Problem

Conventional multifiber ferrule manufacturing methods struggle with precise bumper height tolerances and surface finish quality, particularly in achieving tolerances of 15+/−3 microns and surface roughness of 94 nm Ra, which affect the coplanarity and contact between optical fibers.

Innovation Solution

The use of jig grinding techniques to process multifiber ferrule molding inserts, specifically grinding the bottom surface of the jig grinding wheel, improves bumper height tolerances to 15+/−2 microns and surface finish to 18 nm Ra, enhancing the flatness and surface finish of the region of interest.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional EDM and surface grind processes are used to process ferrule molding inserts, then manufacturing complexity is reduced, but bumper height tolerance and surface finish quality deteriorate

Engineering Contradiction:

Improvebumper height toleranceVSAvoidprocessing complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces conventional EDM (electrical discharge machining) and surface grind processes with jig grinding technology. This mechanical substitution achieves superior bumper height tolerance (15+/−2 microns vs. conventional 15+/−5 microns) and surface finish (18 nm Ra vs. conventional 94 nm Ra) by using precision mechanical grinding rather than electrical or traditional surface grinding methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the processing parameters by introducing jig grinding with specific wheel configurations (bottom surface grinding vs. conventional side grinding). This parameter change enables precise control of bumper height and surface finish quality, transforming the manufacturing capability from conventional tolerances to improved tolerances of 15+/−2 microns for bumper height and 18 nm Ra for surface finish.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If conventional surface grinding is used on the region of interest, then processing time is reduced, but surface finish quality deteriorates

Engineering Contradiction:

Improvesurface finish qualityVSAvoidprocessing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent replaces conventional surface grinding with jig grinding technology for processing the region of interest. This substitution achieves superior surface finish quality (18 nm Ra vs. conventional 94 nm Ra) by using precision mechanical jig grinding with controlled wheel contact, eliminating the surface finish limitations of traditional surface grinding methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a jig grinding wheel as an intermediary tool between the grinding machine and the ferrule molding insert. This intermediary mechanism provides precise control over the grinding process, enabling superior surface finish quality on the region of interest while maintaining efficient processing through the mediating role of the jig grinding system.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If bumper height tolerance is loosened to conventional 15+/−5 microns, then manufacturing complexity is reduced, but fiber coplanarity and contact quality deteriorate

Engineering Contradiction:

Improvefiber coplanarityVSAvoidbumper height tolerance

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent implements precision control through jig grinding technology that provides feedback mechanisms for maintaining bumper height within tight tolerances of 15+/−2 microns. This feedback control ensures consistent bumper height that directly translates to improved fiber coplanarity and contact quality, preventing the reliability issues that would arise from conventional 15+/−5 micron tolerances.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent changes the bumper height tolerance parameter from conventional 15+/−5 microns to improved 15+/−2 microns through jig grinding technology. This parameter change directly improves fiber coplanarity and contact quality by ensuring more precise bumper height control, which is critical for reliable fiber-to-fiber contact in multifiber connectors.

Inventive Principle:

Principle #35Parameter changes

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 results in improved manufacturing yields with more precise bumper height control and surface finish, ensuring accurate fiber alignment and contact, thereby improving the overall performance of multifiber ferrules.

Implementation Method 1

Methodology Applied

Scientific EffectGrinding: Abrasion

Data Source

PatentUS7806601B2Multifiber ferrule with precision bumpers and methods for making the same

Publication Date: 2010.10.05 CORNING OPTICAL COMMUNICATIONS LLC

AI summary

A multifiber (MF) ferrule produced using a ferrule molding insert that is jig ground in order to improve the tolerance on the bumper height of a molded ferrule and the surface finish on the region of interest (ROI), thus improving manufacturing yields.