Optical Ferrule Resin Composition with Controlled Filler Particle Size
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Solution Overview
Problem
The existing ferrules for optical fibers suffer from impaired material homogeneity due to large particle sizes or aggregates from fillers, which can lead to brittleness and poor polishing quality.
Innovation Solution
A ferrule made from a resin composition containing thermoplastic resin and fillers, where the size of coarse particles and aggregates from the filler are controlled to be 50 μm or less, specifically using silica and carbon particles, to ensure material homogeneity and precision molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If filler particles are used to strengthen the resin composition, then the strength of the ferrule is improved, but large particle sizes or aggregates cause impaired material homogeneity
Solution Approach 1:
The patent applies parameter changes by strictly controlling the particle size parameter of the filler to 50 μm or less. This parameter control prevents the formation of large aggregates while maintaining the strengthening effect of the filler particles in the resin composition, thereby resolving the contradiction between strength improvement and material homogeneity.
2Stability of the object's composition
If filler particles are used to improve dimensional stability, then the temperature characteristics of optical connections are enhanced, but large particles cause brittleness and poor polishing quality
Solution Approach 1:
The patent controls the filler particle size parameter to 50 μm or less, which prevents brittleness and ensures good polishing quality while maintaining dimensional stability. This parameter optimization allows the ferrule to achieve both thermal stability for optical connections and high manufacturing precision for polishing.
3Strength
If conventional resin compositions with fillers are used, then the ferrule achieves sufficient strength, but material homogeneity is impaired leading to reduced reliability
Solution Approach 1:
The patent improves reliability by controlling the filler particle size to 50 μm or less, which ensures homogeneous material distribution while maintaining sufficient strength. This parameter control eliminates the risk of large particles causing connection failures, thereby enhancing the overall reliability of optical fiber connections.
Data Source
AI summary
A ferrule is formed with an optical fiber insertion hole into which an optical fiber is inserted, and includes a resin composition containing a thermoplastic resin and a filler, wherein a size of coarse particles originated from the filler is 50 μm or less, or a size of aggregates originated from the filler is 50 μm or less.