Zero-Draft Optical Ferrule Alignment Features
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Molded optical connectors with draft angles for easy removal often result in imprecise mechanical alignment and potential wedging issues due to limited edge contact, which can affect the precision and reliability of optical connections.
Innovation Solution
Designing optical ferrules and cradles with a combination of first side surface portions having a draft angle for mold removal and smaller second side surface portions with zero draft angle for precise alignment, ensuring that only the zero-draft features provide contact during mating, thereby maintaining alignment without causing wedging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If draft angles are applied to side surfaces for easy mold removal, then ease of manufacture is improved, but mechanical alignment precision deteriorates due to limited contact area and potential wedging
Solution Approach 1:
The side surface is segmented into multiple portions: a first side surface portion with a draft angle for mold removal, and a second side surface portion with minimal or zero draft angle for precise mechanical alignment. This segmentation allows each portion to fulfill its specific function independently, resolving the contradiction between ease of manufacture and alignment precision.
Solution Approach 2:
Different portions of the side surface are assigned different draft angles based on their functional requirements. The first portion has a larger draft angle optimized for mold removal, while the second portion has a smaller draft angle optimized for mechanical alignment. This local differentiation of geometric properties enables simultaneous optimization of both manufacturing ease and alignment precision.
2Manufacturing precision
If zero-draft angles are used for alignment surfaces, then mechanical alignment precision is improved, but ease of manufacture deteriorates due to difficulty in mold removal
Solution Approach 1:
The side surface is divided into functional segments where only the critical alignment portion (second side surface portion) uses zero-draft angle, while non-critical portions (first side surface portion) use larger draft angles for easy mold removal. This selective application of zero-draft geometry minimizes manufacturing difficulties while preserving alignment precision.
Solution Approach 2:
Zero-draft angle geometry is applied locally only to the second side surface portion where mechanical alignment is critical, rather than to the entire side surface. This localized approach maintains alignment precision where needed while allowing easier mold removal in other areas.
3Ease of manufacture
If larger draft angles are used for mold removal, then ease of manufacture is improved, but alignment reliability deteriorates due to increased wedging effects
Solution Approach 1:
The side surface is segmented into a first portion with larger draft angle for mold removal and a second portion with minimal draft angle for stable alignment. This segmentation isolates the wedging effect to non-critical areas while protecting the alignment interface from destabilizing forces.
Solution Approach 2:
Different draft angle magnitudes are assigned to different portions of the side surface based on functional importance. The first portion has larger draft angles optimized for mold removal, while the second portion has smaller draft angles optimized for alignment stability, reducing wedging effects at the critical interface.
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 approach allows for precise mechanical and optical alignment of optical components while facilitating easy removal from molds, enhancing the reliability and precision of optical connections by minimizing the impact of draft angles on mating surfaces.
Implementation Method 1
a light redirecting member for receiving light from an optical waveguide attached to the attachment area along a first direction and redirecting the received light along a different second direction
Data Source
AI summary
A molded optical ferrule configured to mate with a mating component includes a top surface, a bottom surface opposite the top surface, and a plurality of side surfaces joining the top and bottom surfaces. The plurality of side surfaces includes a plurality of first side surface portions and a plurality of second side surface portions. The first side surface portions make a first angle greater than zero degrees with a thickness direction of the optical ferrule, the first angle assisting in the removal of the optical ferrule from a mold. The plurality of second side surface portions extends outwardly from the first side surface portions and makes a second angle less than the first angle with the thickness direction. When the optical ferrule mates with the mating component, at least some of the second, but not the first, side surface portions contact corresponding side surface portions of the mating component.