Optical Connector Resin Body with Segmented Core Pin Reflection Surfaces
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Solution Overview
Problem
Conventional optical connectors face challenges in forming precise micro curved surfaces for internal reflection, which are essential for high-accuracy light collection and connection efficiency, due to the complexity of manufacturing such configurations in metal molds.
Innovation Solution
The optical connector features an optical connector body formed by resin molding with bottomed holes containing internal reflection surfaces, where the reflection surfaces are configured to reflect light from optical fibers to optical elements, and the use of adhesive-filled concave portions ensures accurate positioning and secure connection, allowing for easy formation of high-accuracy micro curved surfaces using separable core pins in the metal mold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple micro curved surfaces are formed in one metal mold surface for resin molding, then manufacturing precision of internal reflection surfaces is improved, but device complexity and ease of manufacture deteriorate
Solution Approach 1:
The invention divides the metal mold into multiple independent core pins, each forming one micro curved surface. This segmentation allows each core pin to be independently manufactured and adjusted, achieving high manufacturing precision for multiple internal reflection surfaces without requiring a complex integrated mold structure.
Solution Approach 2:
The invention introduces core pins as intermediary elements that mediate between the simple metal mold structure and the required complex micro curved surfaces. These core pins serve as removable inserts that can be precisely manufactured separately and positioned within the mold cavity to form the desired reflection surfaces.
2Manufacturing precision
If multiple micro curved surfaces are formed in one metal mold surface for resin molding, then manufacturing precision of internal reflection surfaces is improved, but ease of manufacture deteriorates
Solution Approach 1:
By segmenting the mold into separate core pins, each pin can be manufactured using standard precision machining techniques independently. This makes the overall manufacturing process easier compared to attempting to machine multiple precise curved surfaces on a single complex mold surface.
Solution Approach 2:
The core pins act as intermediary components that simplify the manufacturing process. Instead of directly forming complex micro curved surfaces on the main mold, the process is broken down into manufacturing simple core pins that will create the desired surfaces when inserted into the mold cavity.
3Loss of energy
If conventional internal reflection surfaces are used in optical connectors, then light collection efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The invention employs curved surfaces (spherical, elliptical, paraboloidal, or hyperboloidal) on the core pins to achieve effective light reflection and collection. These curved geometries optimize light path control while maintaining relative manufacturing simplicity through standardized forming techniques.
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 the manufacturing of optical connectors with high-accuracy internal reflection surfaces, reduces production costs, and enhances light collection efficiency by allowing for precise alignment and easy modification of reflection surface configurations without requiring a complete new metal mold for each design change.
Implementation Method 1
The internal reflection is a reflection of light in an optical connector body, through which the light passes. The reflection is generated in an interface between the body and an exterior thereof (such as air).
Data Source
AI summary
An optical connector body is formed by an optically-transparent resin molding. The optical connector body includes an optical fiber insertion hole formed parallel to a board surface, a wall with which an optical fiber provided at a front of the optical fiber insertion hole contacts, and an internal reflection surface adjacent to and in front of the wall. The internal reflection surface is formed at a bottom surface of a bottomed hole opened from outside in the optical connector body.