Optical Connector Ferrule Without Fiber Grooves for Mold Strength
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Solution Overview
Problem
Miniaturization of ferrules for optical connectors poses challenges in forming fiber grooves, which affects the strength of the mold and the workability of assembling optical connectors.
Innovation Solution
A ferrule design with fiber holes having inner diameters ranging from 204.6 to 230.0 μm, and a configuration where the upper and lower surfaces of the ferrule main body are covered with a wall surface, allowing for secure workability without a guide groove.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a ferrule is miniaturized to connect more optical fibers within limited space, then the number of optical fibers that can be connected increases, but it becomes difficult to form a fiber groove for introducing optical fibers into fiber holes
Solution Approach 1:
The patent removes the fiber groove structure from the ferrule design. Instead of having grooves that guide fibers into holes, the ferrule directly forms holes that receive fibers. This extraction of the groove element simplifies the molding process and enables ferrule miniaturization while maintaining manufacturability.
Solution Approach 2:
The patent specifies precise parameter ranges for the fiber hole inner diameters (204.6 to 230.0 μm) and distances between adjacent holes (20 μm or more). These parameter optimizations allow the ferrule to be miniaturized while ensuring that fibers can still be properly inserted and that the mold strength is sufficient for injection molding.
2Strength
If the upper surface and lower surface of the ferrule main body are all covered with a wall surface without a guide groove, then the mold strength for injection-molding is maintained, but it becomes difficult to secure workability in assembling the optical connector
Solution Approach 1:
The patent optimizes the inner diameter parameter of the fiber hole rear end opening to be 204.6 to 230.0 μm. This parameter change allows the hole to be large enough to accommodate fiber position variations during assembly while keeping the wall surfaces intact for mold strength. The specific dimension range balances structural integrity with assembly workability.
3Ease of operation
If the inner diameter of the fiber hole is increased to accommodate fiber position variations, then workability in assembling is improved, but the distance between adjacent fiber holes decreases, affecting mold strength
Solution Approach 1:
The patent defines a specific parameter range for the inner diameter of fiber hole rear end openings (204.6 to 230.0 μm) and establishes that the distance between adjacent holes should be 20 μm or more. This parameter optimization allows sufficient clearance for fiber insertion while maintaining adequate material between holes for mold strength during injection molding.
Solution Approach 2:
The patent provides some excess capacity in the fiber hole inner diameter (up to 230.0 μm) to accommodate fiber position variations beyond the minimum required. This excessive dimension provides a margin of error for assembly workability while the lower bound (204.6 μm) ensures sufficient spacing for mold strength.
Data Source
AI summary
A ferrule for an optical connector includes: a ferrule main body including: a connection end surface; an upper surface; a lower surface opposite to the upper surface in a vertical direction, and fiber holes into which optical fibers are inserted along a front-rear direction perpendicular to the vertical direction, and that are arranged in a left-right direction perpendicular to the vertical direction and the front-rear direction. The connection end surface is disposed on a front side in the front-rear direction. Inner diameters of rear end openings of the fiber holes are in a range of 204.6 to 230.0 μm, wherein the rear end openings are disposed on a rear side opposite to the front side in the front-rear direction. A wall surface covers an entirety of the upper surface and the lower surface.