Optical Connector Ferrule Hexagonal Fiber Hole Arrangement
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Solution Overview
Problem
Existing ferrules for optical connectors experience an increase in size in the insertion direction as the number of fiber rows increases, making it difficult to efficiently insert optical fibers due to the constant dimensions of guide grooves in existing designs.
Innovation Solution
The ferrule design incorporates a hexagonal packing arrangement of fiber holes with first and second fiber holes, where second fiber holes are positioned shifted by half the pitch, and longer guide grooves for second fiber holes facilitate easier insertion of optical fibers, allowing first fibers to be guided through concave portions formed by second fibers, even with shorter first guide grooves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If guide grooves are formed stepwise with constant dimensions in each step, then manufacturing is simplified, but the ferrule size increases in the insertion direction according to the number of fiber rows
Solution Approach 1:
The patent applies local quality by making the guide grooves have different lengths in the insertion direction depending on their position. Specifically, guide grooves for second fiber holes (in intermediate rows) are made longer than guide grooves for first fiber holes (in outer rows). This localized differentiation allows the ferrule to maintain a compact overall length while providing sufficient guidance for fibers in intermediate rows, resolving the contradiction between manufacturing simplicity and ferrule length reduction.
2Quantity of substance
If fiber holes are arranged in multiple rows to increase fiber capacity, then the number of optical fibers increases, but the ferrule dimension in the insertion direction increases
Solution Approach 1:
The patent utilizes hexagonal packing arrangement of fiber holes in a two-dimensional pattern, allowing multiple rows of fibers to be accommodated without proportionally increasing the insertion direction length. Combined with the differentiated guide groove lengths, this dimensional arrangement enables higher fiber capacity while controlling the ferrule's length in the insertion direction.
Solution Approach 2:
By providing longer guide grooves only for second fiber holes in intermediate rows and shorter guide grooves for first fiber holes in outer rows, the patent optimizes the structure to accommodate multiple fiber rows without requiring uniform increases in ferrule length throughout, thus increasing fiber capacity while controlling overall dimensions.
3Ease of manufacture
If all guide grooves have the same dimension, then manufacturing is simplified, but insertion smoothness is reduced for fibers requiring longer guidance
Solution Approach 1:
The patent implements local quality by differentiating guide groove lengths based on the specific insertion requirements of different fiber positions. Second fiber holes in intermediate rows receive longer guide grooves for smoother insertion, while first fiber holes in outer rows use shorter guide grooves. This localized optimization maintains manufacturing feasibility while significantly improving insertion smoothness where needed.
Data Source
AI summary
A ferrule for an optical connector includes: a body portion having fiber holes into which optical fibers are inserted, and a connecting end face through which the fiber holes are opened. The fiber holes include: first fiber holes disposed at a predetermined pitch in a first direction on the connecting end face; and second fiber holes disposed at the predetermined pitch in the first direction and at positions different from positions of the first fiber holes in a second direction orthogonal to the first direction. The positions of the second fiber holes are shifted by substantially half the predetermined pitch in the first direction with respect to the positions of the first fiber holes. A rear side of the body portion is opposite to the connecting end face in an insertion direction of the fiber holes.