Pre-Routed Optical Fiber Assembly for Reliable Connector Installation
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Solution Overview
Problem
Existing fiber optic connector systems face inefficiencies in assembly and manufacturing due to the lack of pre-processed and pre-tested optical fibers, leading to increased costs and discarded devices from failed connections.
Innovation Solution
Pre-processing and pre-testing optical fibers before routing them on flexible substrates using a robotic device guided by a digital map, allowing for efficient assembly by aligning fiber ends with multi-dimensional connection locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If optical fibers are assembled without pre-processing and pre-testing, then assembly speed is faster, but manufacturing reliability deteriorates due to increased failed connections
Solution Approach 1:
The patent implements pre-processing and pre-testing of optical fibers before final assembly. Optical fibers are pre-connectorized with ferrules and connectors, pre-routed on flexible substrates, and pre-tested for optical performance compliance. This preliminary action filters out defective fibers early, ensuring only qualified components proceed to final assembly, thereby improving connection reliability without significantly delaying production.
2Reliability
If optical fibers are pre-processed and pre-tested, then manufacturing reliability improves, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into distinct modular stages: pre-processing (ferrule attachment, connector installation), pre-routing (positioning on flexible substrates), and pre-testing (optical performance verification). Each stage is independently controlled and documented, making the complex process manageable and traceable. This segmentation allows for specialized equipment and personnel at each stage, reducing overall process complexity despite the increased number of steps.
3Loss of substance
If pre-testing is performed on optical fibers, then loss of substance decreases due to reduced discards, but loss of time increases due to testing requirements
Solution Approach 1:
Optical fiber testing is performed as a preliminary action during the pre-processing stage, before final assembly and installation. By identifying and removing defective fibers early in the process, the patent prevents time-consuming rework and device discards later in the production cycle. The testing is integrated into the pre-processing workflow, minimizing additional time overhead while maximizing the prevention of substance loss through early defect detection.
Data Source
AI summary
The present disclosure relates to fiber management systems and methods for facilitating assembling fiber optic devices in an efficient manner by allowing pre-processed and tested optical fibers to be pre-routed on a substrate prior to installation in their corresponding fiber optic devices.