Optical Connector Preloaded Meltable Adhesive for Rapid Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing optical fiber connectors require long adhesive cure times, limiting throughput and necessitating batch processing, as they rely on adhesives that take significant time to bind optical fibers effectively.
Innovation Solution
An optical fiber connector preloaded with a meltable, solid adhesive composition that is stored for extended periods and quickly solidifies upon heating, allowing for rapid coupling of optical fibers by melting the adhesive and guiding it into a micro-hole, thereby securing the fiber with a thin layer of adhesive.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional adhesives are used to bind optical fibers to connectors, then reliable bonding is achieved, but processing time increases significantly due to long cure times
Solution Approach 1:
The patent changes the physical state parameter of the adhesive from liquid to solid, and changes the bonding mechanism from chemical curing to thermal melting. The solid adhesive composition melts at a specific temperature (e.g., 80°C to 200°C) to form a bonding layer, eliminating the need for long chemical cure times while maintaining reliable bonding between the optical fiber and connector ferrule
Solution Approach 2:
The patent utilizes phase transition of the solid adhesive composition from solid to liquid state through heating. The adhesive melts at a controlled temperature range to create a flowable bonding layer that can be precisely positioned, then solidifies upon cooling to provide strong mechanical bonding, replacing traditional chemical curing processes
2Reliability
If batch processing is used to accommodate adhesive cure times, then quality control is maintained, but productivity decreases
Solution Approach 1:
The solid adhesive composition is pre-loaded into the connector ferrule before optical fiber assembly, eliminating the need for adhesive injection during the bonding process. This preliminary preparation allows for rapid thermal melting and bonding when the optical fiber is inserted, enabling single-piece flow processing while maintaining consistent bonding quality
Solution Approach 2:
The patent replaces the chemical curing system with a thermal melting system. By using heat to melt the solid adhesive instead of relying on chemical reactions, the process time is dramatically reduced from minutes or hours to seconds, enabling continuous processing and significantly increasing manufacturing throughput
3Manufacturing precision
If adhesive injection is performed immediately before fiber coupling, then adhesive placement precision is improved, but process complexity increases
Solution Approach 1:
The solid adhesive composition is pre-positioned in a reservoir or channel within the connector ferrule during ferrule manufacturing. This preliminary placement ensures precise adhesive location without requiring complex injection systems, and the thermal melting process naturally distributes the adhesive to the optimal bonding position when the optical fiber is inserted
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 solution significantly increases the speed of optical fiber coupling, reduces processing time, and eliminates the need for immediate adhesive injection, enabling single-piece flow and faster attachment processes compared to traditional methods.
Implementation Method 1
following melting and solidification of the adhesive composition
Implementation Method 2
following melting and solidification of the adhesive composition
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
An optical fiber connector preloaded with an adhesive is provided. The optical connector includes a body having a passage with a first section extending inwardly from a first face of the body, a second section extending inwardly from a second face from the body, and a transition section located between the first section and the second section. The first section of the passage has a first width and the second section of the passage has a second width that is less than the first width. A meltable adhesive composition is located within the transition section of the passage and is configured to bind an optical fiber to an inner surface of the second section following melting and solidification of the adhesive composition.