Optical Connector Manufacturing with Solid Refractive Index Layer
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Solution Overview
Problem
The manufacturing of optical connectors faces challenges in minimizing connection loss due to damage to solid refractive index-matching materials and irregularities on the end faces of optical fibers, particularly when using low-cost, simple-type cutters, and the introduction of air bubbles or foreign substances with liquid refractive index-matching materials under high-temperature conditions.
Innovation Solution
A method involving a ferrule with a fiber hole where the first optical fiber, equipped with a solid refractive index-matching material layer, is held by a pair of holding members and inserted inclined into the ferrule, using a slider with a forward-movement limiter to prevent damage to the refractive index-matching material and ensure proper alignment, and a connection mechanism with a base and lid member to align and secure the fibers, allowing for a solid refractive index-matching material layer to be interposed between the optical fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple-type optical fiber cutter is used to reduce cost, then device complexity is reduced, but manufacturing precision deteriorates due to difficulty in keeping cutting conditions constant, resulting in micro irregularities such as hackle marks on the front end face
Solution Approach 1:
A solid refractive index-matching material layer is introduced as an intermediary between the optical fiber end face and the connection interface. This layer compensates for the negative effects of cutting irregularities by filling in micro defects and providing a smooth optical interface, thereby maintaining low connection loss even when using simple-type cutters that produce hackle marks or protrusions
Solution Approach 2:
The refractive index of the solid refractive index-matching material layer is specifically designed to match that of the optical fiber core. By changing the optical parameter (refractive index) of the interface material, the patent eliminates reflection losses and minimizes the impact of surface irregularities on connection performance
2Loss of energy
If liquid refractive index-matching material is used to reduce connection loss, then connection loss is reduced, but reliability deteriorates under high-temperature conditions due to increased flowability causing air bubbles or foreign substances to enter the air gap
Solution Approach 1:
The patent uses a solid refractive index-matching material layer instead of liquid, representing a phase transition from liquid to solid state. This solid material maintains its shape and position under high-temperature conditions, preventing the flowability issues and air bubble formation that occur with liquid materials, while still providing effective refractive index matching for low connection loss
Solution Approach 2:
The solid refractive index-matching material layer is formed as a thin, integrated layer that is permanently bonded to the optical fiber end face. This disposable-like approach eliminates the need for separate application and positioning steps, and ensures consistent performance without the reliability issues of liquid materials under high-temperature operation
3Productivity
If the built-in optical fiber is held and inserted into the fiber hole during manufacturing, then productivity is improved, but reliability deteriorates due to damage to the solid refractive index-matching material
Solution Approach 1:
The solid refractive index-matching material layer is formed on the optical fiber end face before the insertion process. This preliminary action ensures that the protective layer is already in place to prevent damage during subsequent handling and insertion operations, maintaining both productivity and material integrity
Solution Approach 2:
The solid refractive index-matching material layer acts as a cushioning protective layer during the insertion process. This beforehand cushioning prevents direct contact and potential damage to the fiber end face during handling, while still allowing for efficient automated insertion operations
Data Source
AI summary
A method of manufacturing an optical connector according to the invention includes: holding a first optical fiber by a pair of holding members at a position apart from an end face of a second end and through both sides thereof in a radial direction, the first optical fiber being provided with a solid refractive index-matching material layer, the refractive index-matching material layer being formed on the end face of the second end on an opposite side of an end face of a first end exposed to a front end of a ferrule; and inserting the first optical fiber into a fiber hole of the ferrule through the first end.