Optical Connector Manufacturing Rotational Alignment
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Solution Overview
Problem
Existing methods for manufacturing optical connectors with multi-core fibers face challenges in maintaining precise rotational alignment, leading to core position deviations and increased splicing loss due to insufficient control over the distance between the glass fiber and ferrule end surfaces during the rotational alignment process.
Innovation Solution
A method involving coating the ferrule's inner hole with thermosetting resin, inserting and adjusting the glass fiber to maintain a distance of ≤1 mm between the fiber and ferrule end surfaces, followed by rotational alignment and polishing to minimize core position changes and splicing loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the glass fiber is inserted into the ferrule without controlling the distance between end surfaces, then the insertion process is simpler, but the rotational alignment precision deteriorates leading to core position deviations
Solution Approach 1:
The patent applies preliminary action by controlling the distance between the glass fiber end surface and ferrule end surface to be 0.5 mm or less before rotational alignment. This pre-positioning ensures that when rotational alignment is performed, the core position deviation remains within acceptable limits (5 μm or less), thereby resolving the contradiction between insertion simplicity and alignment precision.
2Loss of substance
If the distance between glass fiber end surface and ferrule end surface is increased, then the polishing amount is reduced, but the core position deviation increases leading to higher splicing loss
Solution Approach 1:
The patent applies parameter changes by optimizing the distance parameter between the glass fiber end surface and ferrule end surface to be 0.5 mm or less. This parameter control enables rotational alignment to be performed with minimal polishing (reducing material loss) while maintaining core position deviation within 5 μm, thus achieving both reduced polishing amount and low splicing loss.
3Productivity
If rotational alignment is performed without controlling the initial distance, then the alignment process is faster, but the core position accuracy deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-controlling the distance between end surfaces to 0.5 mm or less before rotational alignment. This allows the alignment process to proceed quickly without requiring extensive polishing or adjustment, while still achieving high core position accuracy (deviation within 5 μm), thus resolving the contradiction between alignment speed and accuracy.
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 ensures a low splicing loss and precise core position control, reducing deviations and polishing amounts, thereby enhancing the accuracy and efficiency of optical connector manufacturing.
Implementation Method 1
coating an inner wall of the through hole with a thermosetting resin; inserting the glass fiber exposed from the resin coating into the through hole; curing the thermosetting resin
Data Source
AI summary
Provided is a method for manufacturing an optical connector. The optical connector includes: an optical fiber including a glass fiber and a resin coating; and a ferrule including a through hole. The method for manufacturing includes: coating an inner wall of the through hole with a thermosetting resin; inserting the glass fiber exposed from the resin coating into the through hole; adjusting a mutual positional relationship between the optical fiber and the ferrule so that a distance between end surfaces of a tip of the glass fiber and a tip of the ferrule is equal to or less than 1 mm; rotationally aligning the glass fiber with respect to the ferrule; curing the thermosetting resin; and polishing the tip of the glass fiber and the tip of the ferrule.