Optical Connector Housing with Front-Access Windows for Epoxy Control

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Solution Overview

Problem

Assembling optical connectors is challenging due to the difficulty in visualizing and controlling the epoxy placement within the ferrule assembly, which often results in epoxy wicking back along the lead-in tube, making it hard to secure the optical fiber properly.

Innovation Solution

A unitary connector housing design with windows allows for visual inspection and prevents epoxy wicking, featuring a ferrule assembly with a single ferrule and holder that can be inserted from the front, and a method involving syringes and lead-in tubes to accurately place and cure epoxy within the ferrule assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If epoxy is inserted from the back end of the ferrule assembly, then the ferrule assembly can be secured together, but it is difficult to see where and how much epoxy is disposed and the epoxy wicks back along the lead-in tube

Engineering Contradiction:

Improveepoxy placement controlVSAvoidepoxy placement visibility

Core Design Contradiction:

Manufacturing precisionVSDifficulty of detecting and measuring

Solution Approach 1:

The patent inverts the traditional epoxy insertion approach by providing access to the ferrule assembly from the front end rather than the back end. The first opening in the connector housing allows epoxy to be injected directly into the ferrule assembly from the front, enabling visual inspection and precise control of epoxy placement while preventing wicking back along the lead-in tube.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent introduces a lead-in tube as an intermediary structure that guides epoxy placement. The lead-in tube extends from the first opening and positions the epoxy precisely at the fiber tip, ensuring accurate placement and preventing uncontrolled wicking. The tube acts as a mediator between the epoxy injection point and the fiber termination point.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If a two-piece housing is used with ferrule assembly inserted from the back end, then the connector can be assembled, but visual inspection is not possible and assembly complexity increases

Engineering Contradiction:

Improveassembly simplicityVSAvoidhousing structure

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges the housing structure into a unitary single-piece design rather than using a two-piece construction. The connector housing is formed as a single molded piece with integrated features including the first opening for epoxy injection, the second opening for fiber access, and the recess for the ferrule assembly. This simplifies manufacturing while enabling front-end access for both epoxy injection and visual inspection.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The unitary connector housing performs multiple functions: it provides structural support, contains the ferrule assembly, allows epoxy injection from the front, enables visual inspection through openings, and guides the lead-in tube. This multi-functional design eliminates the need for separate housing pieces while simplifying the overall assembly process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If epoxy is injected without visual inspection capability, then assembly can proceed, but epoxy placement precision is compromised leading to wicking issues

Engineering Contradiction:

Improveassembly speedVSAvoidepoxy placement accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent enables preliminary visual inspection of epoxy placement through the first opening before the epoxy cures. This allows the operator to verify that the epoxy has been correctly positioned at the fiber tip and has not wicked back along the lead-in tube, ensuring placement accuracy while maintaining efficient assembly throughput.

Inventive Principle:

Principle #10Preliminary action

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 enables precise placement and curing of epoxy, preventing wicking and ensuring secure optical fiber insertion, thus improving the assembly efficiency and reliability of optical connectors.

Implementation Method 1

curing the epoxy to secure the optical fiber in the ferrule holder and the single ferrule

Methodology Applied

Scientific EffectCuring: Photopolymerisation

Implementation Method 2

the ferrule assembly and connector housing have windows therein to allow visual inspection and to prevent the wicking of the epoxy to the lead-in tube

Methodology Applied

Scientific EffectWicking prevention: Capillary Action

Data Source

PatentUS10928595B2Optical connector element

Publication Date: 2021.02.23 ROSSON JOEL C

AI summary

An optical connector has a single ferrule held within a ferrule holder to make a ferrule assembly. The ferrule assembly is inserted into a connector housing with an expansion slot extending from the front end toward the back end to allow insertion of the ferrule assembly from the front of the connector housing. The ferrule holder has at least one extension extending from a outer surface thereof and a window in communication with and opening extending through the ferrule holder. The connector housing also has a window disposed in the main body, the window disposed in the main body in an outer surface adjacent the expansion slot to receive the extension from the ferrule holder.