Optical Connector Metal Intermediate Member Design

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Solution Overview

Problem

Existing optical connectors face issues with strength and shape accuracy when the plastic intermediate member is thinned, leading to potential assembly problems and reduced working efficiency due to warping or distortion, especially when trying to adjust the size of the ferrule and holder member without modifying the plug.

Innovation Solution

Incorporating a metal intermediate member formed by bending a metal plate between the holder member and the plug, ensuring strength and precision while allowing for size adjustments without altering the plug's shape, thereby enhancing assembly efficiency and accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the plastic intermediate member is thinned to reduce the size of the unit of the ferrule and holder member, then the size is reduced, but the intermediate member may be readily warped or distorted and the strength becomes weaker

Engineering Contradiction:

Improvesize of the unit of the ferrule and holder memberVSAvoidstrength of the intermediate member

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The patent changes the material parameter of the intermediate member from plastic to metal, which fundamentally alters the strength-to-thickness ratio. This material substitution allows the intermediate member to maintain sufficient strength even when thinned, thereby enabling size reduction without compromising structural integrity.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The optical connector employs a composite structure where the intermediate member is formed of metal while other components remain plastic. This selective use of materials optimizes the strength requirements specifically for the intermediate member, allowing it to be thinned without affecting overall assembly strength.

Inventive Principle:

Principle #40Composite materials

2Volume of moving object

If the plastic intermediate member is thinned, then the size is reduced, but the shape accuracy of the intermediate member becomes low due to warping or distortion

Engineering Contradiction:

Improvesize of the intermediate memberVSAvoidshape accuracy of the intermediate member

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

Changing the material from plastic to metal fundamentally improves the dimensional stability and rigidity of the intermediate member. Metal materials have higher modulus of elasticity, which prevents warping and distortion during assembly, thereby maintaining high shape accuracy even when the member is thinned.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Instead of trying to prevent warping by thickening the plastic member, the patent inverts the approach by using metal material that inherently resists warping. This inversion of the problem-solving strategy allows for thinning while maintaining precision.

Inventive Principle:

Principle #13The other way round (Inversion)

3Strength

If the plastic intermediate member is warped or distorted, then the strength is reduced, but there is a possibility that a problem arises in fitting the units together during assembly

Engineering Contradiction:

Improvestrength of the intermediate memberVSAvoidease of assembly of the units

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The material substitution from plastic to metal ensures that the intermediate member maintains its shape and strength during assembly operations. The higher rigidity of metal prevents deformation under handling stresses, making the assembly process smoother and more reliable.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS8297851B2Optical connector

Publication Date: 2012.10.30 FURUKAWA ELECTRIC CO LTD

AI summary

An optical connector 1 includes a plastic ferrule 4 that holds optical fibers 7, a plastic holder member 61 that holds the ferrule 4, a plastic plug 6 that is arranged outside the holder member 61, and a metal intermediate member 5 that is disposed between an outer surface of the holder member 61 and an inner surface of the plug 6.