Optical Cable Terminus Assembly Using Crimped Shell Alignment
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Solution Overview
Problem
Existing terminus assemblies for optical cables are complex and costly due to the need for alignment sleeves and ferrules, which can be fragile and labor-intensive to secure, leading to reliability issues and increased complexity.
Innovation Solution
A terminus assembly for plastic optical fibers that eliminates the need for alignment sleeves and ferrules by using a crimped shell and crimp sleeve to secure the optical cable, aligning the fiber ends within a mating receptacle for reliable optical coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If alignment sleeves and ferrules are used to align fiber tips, then alignment precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent removes alignment sleeves and ferrules from the connector system, retaining only the essential crimped shell and crimp sleeve components. This extraction of non-essential elements simplifies the device while maintaining alignment functionality through the basic structural arrangement of the crimped components.
Solution Approach 2:
The patent combines the alignment and securing functions into the crimped shell and crimp sleeve structure. The crimped components serve multiple purposes: mechanically securing the optical cable and providing alignment through their integrated geometry, eliminating the need for separate alignment sleeves and ferrules.
2Manufacturing precision
If alignment sleeves and ferrules are used to align fiber tips, then alignment precision is improved, but reliability decreases due to fragile components
Solution Approach 1:
The patent removes the fragile alignment sleeves and ferrules from the system, eliminating their inherent reliability problems. The remaining crimped shell and crimp sleeve components are more robust and less prone to failure during installation and operation.
Solution Approach 2:
The patent employs simple, robust crimped components that are easier to manufacture and less prone to failure. These components are designed for reliability rather than precision adjustment, accepting a trade-off that favors durability and ease of manufacture over fine-tunable alignment precision.
3Manufacturing precision
If ferrules are secured to fiber tips using epoxy, then alignment precision is improved, but manufacturing time and labor intensity increase
Solution Approach 1:
The patent removes ferrules and the epoxy securing process entirely from the manufacturing workflow. This eliminates the time-consuming steps of applying, positioning, and curing epoxy, significantly加快ing the manufacturing process.
Solution Approach 2:
The patent replaces the chemical bonding process (epoxy) with a mechanical crimping system. The crimped shell and crimp sleeve provide secure mechanical attachment of the optical cable and fiber, eliminating the need for chemical adhesives and associated processing steps.
4Manufacturing precision
If alignment sleeves and ferrules are used, then alignment precision is improved, but cost increases
Solution Approach 1:
The patent removes alignment sleeves and ferrules, which are costly components requiring precise manufacturing and assembly. The simplified crimped structure reduces part count and manufacturing complexity, leading to lower production costs.
Solution Approach 2:
The patent employs simple, inexpensive crimped components that are easier and cheaper to manufacture than precision alignment sleeves and ferrules. The design accepts simpler, more cost-effective materials and manufacturing processes while maintaining adequate functionality.
Data Source
AI summary
A terminus assembly is provided for terminating an optical cable that includes a plastic optical fiber (POF) having a tip segment that includes a tip surface. The terminus assembly includes a shell that includes a cable passage. The cable passage is configured to receive at least a portion of a length of the optical cable therein such that the tip segment of the POF extends within the cable passage. A POF stub is held by the shell. The POF stub extends a length from a mating end to a fiber end. The mating end of the POF stub is configured to optically couple with a mating POF of a mating connector. The fiber end of the POF stub includes a coupling surface. The POF stub is held by the shell such that the fiber end extends within the cable passage of the shell. The coupling surface of the fiber end is configured to be aligned with the tip surface of the POF within the cable passage of the shell such that the POF stub is optically coupled to the POF. The POF stub serves as a forward stop for the POF of the optical cable.