Optical Connector Assembly with Mounted Ferrule Cap
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Solution Overview
Problem
The conventional method of assembling optical connectors, where a protection cap is removed from the ferrule during the joining of the plug frame to the rear housing, often results in the coated optical fiber being pulled or twisted, leading to breakage and poor workability.
Innovation Solution
The method involves fusion-splicing the optical fiber and the built-in fiber while the protection cap is mounted on the ferrule, then assembling the housings together without removing the cap, thereby preventing the fiber from being pulled or twisted, and optionally providing a handle for easier handling during splicing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the protection cap is removed from the ferrule during assembly, then the assembly process can be completed, but the coated optical fiber may be pulled or twisted causing breakage and worsened workability
Solution Approach 1:
The protection cap is mounted on the ferrule before the fusion splicing operation is performed. This preliminary mounting ensures the cap remains in place during subsequent assembly steps, preventing fiber damage while allowing the assembly to proceed. The cap serves as a protective element that is already positioned before the critical splicing action occurs.
2Ease of operation
If the protection cap remains mounted on the ferrule during housing assembly, then fiber breakage is prevented, but additional handling steps are required
Solution Approach 1:
The protection cap is designed with a distinct handle portion that can be separately grasped and manipulated. This segmentation allows the operator to hold and position the ferrule assembly through the handle without affecting the mounted cap, enabling complex positioning tasks to be performed without requiring cap removal or additional manipulation steps.
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 enhances workability by eliminating the risk of fiber breakage during assembly and simplifies the process by maintaining the protection cap on the ferrule, ensuring the optical connector is assembled without compromising the integrity of the optical fiber.
Implementation Method 1
fusion-splicing the optical fiber introduced in the second housing and the built-in fiber to each other
Data Source
Figure 1(a)~1(b)
Figure 2
Figure 3
AI summary
An optical connector assembling method capable of preventing workability from worsening is provided. First, when assembling the optical connector, an optical cord (2) is passed through a rear housing (8), an outer jacket holding member (9), a securing member (10), and a boot (11), and an outer jacket (4) is removed from a leading end portion of the optical cord (2), so as to expose a coated optical fiber (3) and a tension-resistant fiber (5). A handled dust cap (16A) is mounted to a ferrule member (6) holding a built-in fiber. Then, a fusion splicer fusion-splices the built-in fiber and the coated optical fiber (3) to each other. Thereafter, while the ferrule member (6) keeps the handled dust cap (16A) mounted thereto, a plug housing (7) is assembled to the rear housing (8). Then, the outer jacket holding member (9) and securing member (10) secure the outer jacket (4) and tension-resistant fiber (5) to the rear housing (8), and the boot (11) is mounted to the securing member (10). Finally, a handle (16a) is cut off from the handled dust cap (16A).