Optical Connector Sleeve Relocation for Molding Defect Reduction

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Solution Overview

Problem

The existing optical-fiber connection units face challenges with defective molding of sleeve holders, difficulty in confirming molding defects, increased manufacturing costs due to separate molding of optical adapter components, and the need for multiple dust caps, which reduces yield and increases costs.

Innovation Solution

The optical-fiber connection unit design relocates the split sleeve and sleeve holder to the optical connector, eliminating the need for them within the optical adapter, simplifying the adapter's shape, allowing easier molding and defect detection, reducing the need for separate dust caps, and enabling integral molding of the adapter.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the sleeve holder is arranged in inner portions of the attachment holes of the optical adapter, then the optical connector can be properly assembled with the split sleeve and sleeve holder, but the molding accuracy of the sleeve holder deteriorates due to difficulty in cooling and curing

Engineering Contradiction:

ImproveassemblyVSAvoidmolding accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The sleeve holder and split sleeve are extracted from the optical adapter and relocated to the optical connector. This allows the sleeve holder to be molded separately from the adapter body, eliminating the cooling and curing issues that occur when the sleeve holder is positioned inside the attachment holes of the adapter during injection molding.

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of manufacture

If the optical adapter is made by injection molding of resin with the sleeve holder surrounded by the casing, then the adapter can be manufactured, but defective molding occurs due to insufficient cooling and curing

Engineering Contradiction:

Improvemanufacturing processVSAvoidmolding quality

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The sleeve holder is extracted from the adapter's internal structure and transferred to the optical connector. This separation allows the adapter to be molded without the cooling and curing problems that arise when the sleeve holder is surrounded by the casing during injection molding.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The system is segmented into two independent components: the optical adapter and the optical connector. The sleeve holder becomes part of the connector assembly rather than the adapter, allowing each component to be molded separately with appropriate cooling and curing conditions.

Inventive Principle:

Principle #1Segmentation

3Ease of operation

If the optical adapter is surrounded by a double-pipe structure of the casing and sleeve holder, then the optical connector can be retained properly, but the adapter becomes difficult to mold and defect detection becomes difficult

Engineering Contradiction:

ImproveretentionVSAvoiddefect detection

Core Design Contradiction:

Ease of operationVSDifficulty of detecting and measuring

Solution Approach 1:

The sleeve holder is extracted from the adapter and placed on the optical connector. This eliminates the double-pipe structure surrounding the adapter, making both the molding process and defect detection significantly easier while maintaining the retention function through the connector's design.

Inventive Principle:

Principle #2Taking out (Extraction)

4Object-affected harmful factors

If multiple dust caps are provided for protecting the ferrule and split sleeve separately, then each component can be protected, but the manufacturing cost increases

Engineering Contradiction:

Improveprotection from contaminationVSAvoidmanufacturing cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The protection function is merged into a single dust cap that covers both the ferrule and the split sleeve together. Since the sleeve holder and split sleeve are now part of the optical connector assembly, one dust cap on the connector provides comprehensive protection for all internal components, eliminating the need for separate dust caps and reducing manufacturing costs.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS8317408B2Optical-fiber connection unit, and optical connector and optical adapter used therein

Publication Date: 2012.11.27 SUNCALL CORP

AI summary

Provided is an optical-fiber connection unit in which a split sleeve (14) for performing centering of distal end portions of ferrules (11 and 111) is provided not to an optical adapter (20) but to an optical connector (10). With this configuration, it is unnecessary to provide a sleeve holder inside a casing (21) of the optical adapter (20), and hence a shape of the optical adapter (20) is simplified. Further, a sleeve holder (13) provided to the optical connector (10) is formed in a state of being exposed outward. Thus, a risk of defective molding is reduced, and presence or absence of defective molding can be easily confirmed.