Thin Ferrule Crack Prevention via Localized Boot Reinforcement
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Solution Overview
Problem
The challenge is to create a thin ferrule for optical connectors that can withstand increased density of information devices without generating cracks during manufacturing or usage, while also ensuring the ferrule boot can be securely inserted and maintain optical fiber protection.
Innovation Solution
The ferrule design features a boot insertion part with a wider width than the ferrule body, a specific ratio of width to height at the boot insertion part, and a minimum wall thickness of 0.32 mm at the thinnest portion. Additionally, the use of PPS resin and strategic ejection pin placement during manufacturing help prevent cracks. The ferrule boot is made from ABS resin to provide necessary flexibility and rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the ferrule is made thinner to support increased device density, then the ferrule height is reduced, but the ferrule becomes more prone to cracking during manufacturing and usage
Solution Approach 1:
The patent applies local quality by making the boot insertion part wider than the ferrule body, creating a localized structural reinforcement zone. This wider section (with width-to-height ratio of 5 times or more) provides additional structural support and crack resistance precisely where the boot insertion creates stress concentration, while the rest of the ferrule maintains its thin profile to support high device density.
Solution Approach 2:
The patent implements preliminary action by designing the boot insertion part with pre-reinforced geometry (wider width) before the actual boot insertion process. This preemptive structural design ensures that when the boot is inserted and creates stress on the ferrule, the critical area already has enhanced crack resistance due to the wider cross-section, preventing crack initiation and propagation.
2Reliability
If the boot insertion part is made wider to prevent cracking, then crack resistance is improved, but the ferrule width increases reducing device density
Solution Approach 1:
The patent applies local quality by making the boot insertion part wider than the ferrule body, creating a localized structural reinforcement zone. This wider section (with width-to-height ratio of 5 times or more) provides additional structural support and crack resistance precisely where the boot insertion creates stress concentration, while the rest of the ferrule maintains its thin profile to support high device density.
3Length of moving object
If the wall thickness is reduced to make the ferrule thinner, then the ferrule height is reduced, but manufacturing precision becomes more difficult to maintain
Solution Approach 1:
The patent applies local quality by making the boot insertion part wider than the ferrule body, creating a localized structural reinforcement zone. This wider section (with width-to-height ratio of 5 times or more) provides additional structural support and crack resistance precisely where the boot insertion creates stress concentration, while the rest of the ferrule maintains its thin profile to support high device density.
Data Source
AI summary
Provided is a ferrule (100) in which fiber holes (20, 25) for insertion of a plurality of optical fibers are provided in a front end surface (100a), and a boot insertion hole (35) of a boot insertion part (30) for inserting a ferrule boot (102) through which optical fibers are inserted is provided in a rear end surface (100b), wherein the ferrule (100) comprises an internal space that communicates the fiber holes (20) and the boot insertion hole (35), an adhesive filling window (55) of an adhesive filling part (50) for filling the internal space with an adhesive is provided in one surface, the width of the ferrule (100) in the boot insertion part (30) is larger than the width of the ferrule body (10), the ratio of the width to the height of the ferrule (100) in the boot insertion part (30) is 5 or greater, and the wall thickness of the ferrule (100) on the periphery of the boot insertion hole (35) at the thinnest portion thereof is 0.32 mm or greater.