Re-spliceable Splice-on Connector with Extended Rubber Boot
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Solution Overview
Problem
Current techniques for permanently joining optic fibers often result in failures due to poor cleaving, cracks, dirt, accidental over-arc damage, improper fiber arrangement, or bends, making it impractical to rejoin optic fiber end portions using a fusion splicer.
Innovation Solution
Increasing the length of the optic fiber stub portion by extending the associated rubber boot, allowing for up to three opportunities to splice optic fibers correctly and providing improved strain relief and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the length of optic fiber stub portion is increased by extending the rubber boot, then multiple splicing opportunities and strain relief are improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The connector is divided into distinct functional segments: a reusable connector body containing alignment features, and a disposable fiber stub assembly with the rubber boot. This segmentation allows the complex strain relief and alignment functions to be isolated in the reusable portion, while the fiber stub can be easily replaced without affecting the overall connector complexity.
Solution Approach 2:
The rubber boot is pre-formed and pre-assembled with the connector body before fiber installation. The alignment features and strain relief mechanisms are prepared in advance, eliminating the need for complex field adjustments and enabling multiple splicing attempts without increasing operational complexity.
2Strength
If the rubber boot is extended to provide strain relief and multiple splicing opportunities, then the mechanical integrity is improved, but the manufacturing cost and process complexity increase
Solution Approach 1:
The rubber boot material composition and cross-sectional geometry are optimized to provide maximum strain relief with minimal material usage. The extended boot design uses standardized dimensions that can be produced using conventional extrusion and molding processes, maintaining manufacturing simplicity while enhancing mechanical protection.
Solution Approach 2:
The connector assembly combines the elasticity and strain relief properties of rubber boot material with the rigidity and precision of the connector body materials. This composite construction provides superior mechanical integrity while each component can be manufactured using its optimal process.
3Ease of repair
If the optic fiber stub length is increased to allow re-splicing, then the ability to correct splicing failures is improved, but the time and resources required for manufacturing increase
Solution Approach 1:
The fiber stub assembly with the extended rubber boot is designed as a disposable component that can be pre-tested and certified. If splicing fails, the entire stub assembly is replaced rather than attempting to repair the splice, eliminating re-splicing time while the extended boot provides protection during handling and installation.
Solution Approach 2:
The fiber stub is pre-cleaved and pre-positioned in the connector body with alignment features engaged before the actual splicing operation. This preliminary preparation ensures that if splicing fails, the fiber is already positioned correctly for immediate re-attempt, eliminating setup time and enabling rapid correction of splicing failures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution eliminates the need for different connector holders, reduces the cost of failed-splice connections, and enhances the mechanical and electrical integrity of the optic fiber connections.
Implementation Method 1
Employing a fusion splicer technique, an electric arc is used to melt two optic fiber ends together.
Implementation Method 2
an electric arc is used to melt two optic fiber ends together
Implementation Method 3
The rubber boot also connects to the connector, and thereby provides strain relief.
Data Source
AI summary
A method of re-splicing a splice-on connector (“SOC”) includes at least five steps: (1) stripping insulation from an end portion of a first optic fiber; (2) stripping insulation from an end portion of a second optic fiber having a connector body fixed to an opposite end portion thereof. One end portion of the connector body is sized and configured to be inserted into an end portion of an elongated hollow member. The method also includes: (3) splicing together the first and second fiber optic end portions to produce either an SOC or a re-spliced splice-on connector (“RSSOC”). The SOC has a predetermined length to enable cutting at three predetermined locations spaced from the connector body. The method further includes: (4) if an operational fault is caused in a system using the SOC or RSSOC, cutting the SOC or the RSSOC at one of the three predetermined regions; and (5) repeating step (3).