Optical Ferrule Reshaping for Core Concentricity Correction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Optical fiber connectors face significant insertion loss due to core-to-ferrule concentricity errors, which arise from misalignment between the optical fiber core and the ferrule, leading to inefficient optical coupling.
Innovation Solution
A method involving the measurement and reshaping of the ferrule's outer surface to create micro-protuberances or enlarge specific portions, using laser irradiation to adjust the ferrule's diameter and center, thereby improving the alignment between the optical fiber core and the ferrule.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the ferrule is manufactured with standard precision, then the manufacturing cost is low, but the core-to-ferrule concentricity error is significant
Solution Approach 1:
The patent applies preliminary action by measuring the true center of the ferrule before final assembly and using this measurement to guide the reshaping process. The method determines the offset between the core and ferrule center, then selectively enlarges specific portions of the ferrule to correct this offset before the ferrule is fully assembled into the connector, thereby achieving high concentricity without requiring extremely precise manufacturing throughout the entire production process.
Solution Approach 2:
The patent implements local quality by selectively enlarging only specific portions of the ferrule rather than uniformly increasing the entire ferrule dimensions. The method identifies the direction and magnitude of the offset and applies material addition or removal only in the regions that need correction, maintaining the original ferrule geometry in areas that are already properly aligned while modifying only the problematic zones to achieve the desired concentricity.
2Reliability
If the ferrule is reshaped to correct concentricity errors, then the coupling efficiency is improved, but the ferrule geometry is altered
Solution Approach 1:
The patent applies local quality by selectively modifying only specific portions of the ferrule outer surface rather than changing the entire ferrule geometry. The method identifies the offset direction and magnitude, then enlarges or removes material only in the specific regions that need correction, thereby improving coupling efficiency while preserving the original ferrule shape in areas that are already properly aligned.
Solution Approach 2:
The patent implements parameter changes by precisely controlling the dimensions and positions of the enlarged portions or removed material on the ferrule outer surface. The method calculates the required geometric modifications based on measured offset parameters and applies controlled material addition or removal to achieve the target concentricity while minimizing overall geometric changes to the ferrule.
3Manufacturing precision
If material is removed from the ferrule to reshape it, then the concentricity is improved, but the ferrule strength is reduced
Solution Approach 1:
The patent applies partial action by removing or adding material only to the extent necessary to correct the concentricity error, rather than making extensive modifications to the ferrule. The method calculates the minimum required geometric change to achieve the desired alignment, thereby improving concentricity while minimizing the reduction in ferrule strength that would result from excessive material removal.
Solution Approach 2:
The patent implements local quality by concentrating material removal or addition only in the specific regions that need correction rather than uniformly modifying the entire ferrule. This localized approach improves concentricity while preserving the structural integrity and strength of the ferrule in regions where material is not removed, thereby minimizing the overall impact on ferrule strength.
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 reduces core-to-ferrule concentricity errors, enhancing the coupling efficiency and minimizing insertion loss by ensuring better alignment and force distribution within the connector assembly.
Implementation Method 1
creating the crater and the at least one micro-protuberance includes applying a laser beam to irradiate the outer surface of the ferrule
Implementation Method 2
applying a laser beam to irradiate the outer surface of the ferrule, wherein the laser beam has a wavelength ranging between 10 nm and 20,000 nm and an average power delivered to the ferrule between 0.001 μJ/μm2 and 1000 μJ/μm2
Data Source
AI summary
Methods of reshaping ferrules used in optical fiber cables assemblies are disclosed. The reshaping methods reduce a core-to-ferrule concentricity error (E), which improves coupling efficiency and optical transmission. The methods include measuring a true center of the ferrule, wherein the true center is based on an outer surface of the ferrule; and reshaping at least a portion of the ferrule to change the true center of the ferrule, wherein the reshaping includes enlarging a portion of the ferrule. A variety of reshaping techniques are also disclosed.