Overmolded Fiber Optic Connector for Smooth Fiber Insertion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing fiber optic connectors face issues with optical fiber insertion due to obstructions from lead-in tube ridges, ferrules, and hubs, leading to damage and improper epoxy placement.
Innovation Solution
A fiber optic connector design featuring an over-molded lead-in tube made of flexible plastic that fully encapsulates the ferrule hub, with a tapered inner surface to facilitate smooth insertion and prevent epoxy migration, incorporating a retention member like a barb for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a lead-in tube with ridges is used to prevent epoxy migration, then epoxy placement control is improved, but fiber insertion is hindered due to obstructions from the ridges
Solution Approach 1:
The harmful ridges are removed from the lead-in tube surface, extracting the obstruction element while retaining the tube's protective function. This eliminates fiber insertion obstructions while maintaining epoxy containment capability through the tube's wall structure rather than surface ridges.
Solution Approach 2:
Instead of using outward-projecting ridges to prevent epoxy migration, the design uses an inverted approach where the lead-in tube has a smooth interior surface that directs epoxy flow control through its wall structure and geometry, preventing epoxy from migrating outward while maintaining smooth fiber insertion.
2Strength
If a rigid hub structure is used to provide mechanical support, then structural stability is improved, but fiber insertion is damaged due to interference from the hub surface
Solution Approach 1:
The hub structure is differentiated into regions with different surface properties: the exterior maintains a rigid, smooth finish for structural integrity and epoxy containment, while the interior surface that contacts the fiber is made smooth and obstruction-free. This local quality differentiation allows the hub to provide mechanical strength without causing fiber damage during insertion.
3Ease of operation
If a smooth lead-in tube is used to facilitate fiber insertion, then insertion ease is improved, but epoxy containment is compromised due to lack of surface features
Solution Approach 1:
The lead-in tube acts as an intermediary structure that uses its wall thickness and geometric configuration to contain epoxy, rather than relying on surface ridges. The tube's cylindrical form and positioning of the ferrule within it create a natural containment zone for epoxy, preventing migration without requiring obstructive surface features that would harm fiber insertion.
Data Source
AI summary
The present disclosure relates to a fiber optic connector designed to improve the insertion of an optical fiber within the fiber optic connector. The fiber optic connector may include a lead-in tube that makes the insertion of an optical fiber easier. That is, the lead-in tube may be molded over a ferrule hub to fully encapsulate a rear end thereof such that the optical fiber does not snag or hang up during insertion.