Claims Analysis
Total Claims: 6
Claim 1
Independent Claim
324 words
A method for producing a plastic plug ferrule for use in an optical fiber connector, said method comprising the steps of: providing a cylindrical rod having a round hole in the center of one end, said hole having a diameter approximately identical to the diameter of a bare fiber of an optical fiber to be connected; inserting a pin having a cylindrical outer portion and a diameter approximately equal to the diameter of said bare fiber in said round hole, said pin cooperating with said rod to constitute a master mold; electroplating a metal layer having a predetermined thickness on the external surfaces of said master mold to produce an electroformed mass surrounding said master mold except for an end portion of said rod opposite the rod end having said hole therein, said pin being at least partially embedded in said electroformed mass; withdrawing said rod from said electroformed mass to convert said mass to an electroformed mold having a cylindrical recess therein with an end of said pin extending into said recess from the bottom of the recess, said pin being aligned along the central axis of the recess; disposing a cylindrical pipe in said recess with said pipe aligned coaxially with said recess and one end of said pipe spaced a given distance from said end of said pin, to provide a passage for gas to be purged and for excess molten resin to be drained during the subsequent molding step; introducing a fluid plastic resin between the outer surface of said pipe and the inner wall of said recess to produce a cylindrical plastic plug ferrule upon solidification of said fluid resin, said ferrule having a central bore and an end with a hole therein aligned with said central bore; and removing any plastic material between said hole in the end of said ferrule and said central bore, so that said central bore of said ferrule communicates with said hole therein.
Claim 2
Independent Claim
324 words
A method for producing a plastic plug ferrule for use in an optical fiber connector, said method comprising the steps of: providing a cylindrical rod having a round hole in the center of one end, said hole having a diameter approximately identical to the diameter of a bare fiber of an optical fiber to be connected; inserting a pin having a cylindrical outer portion and a diameter approximately equal to the diameter of said bare fiber in said round hole, said pin cooperating with said rod to constitute a master mold; electroplating a metal layer having a predetermined thickness on the external surfaces of said master mold to produce an electroformed mass surrounding said master mold except for an end portion of said rod opposite the rod end having said hole therein, said pin being at least partially embedded in said electroformed mass; withdrawing said rod from said electroformed mass to convert said mass to an electroformed mold having a cylindrical recess therein with an end of said pin extending into said recess from the bottom of the recess, said pin being aligned along the central axis of the recess; disposing a cylindrical pipe in said recess with said pipe aligned coaxially with said recess and one end of said pipe spaced a given distance from said end of said pin, to provide a passage for gas to be purged and for excess molten resin to be drained during the subsequent molding step; introducing a fluid plastic resin between the outer surface of said pipe and the inner wall of said recess to produce a cylindrical plastic plug ferrule upon solidification of said fluid resin, said ferrule having a central bore and an end with a hole therein aligned with said central bore; and removing any plastic material between said hole in the end of said ferrule and said central bore, so that said central bore of said ferrule communicates with said hole therein.
Claim 3
Dependent Claim
19 words
The method according to claim 1, wherein said given distance is in the range of 1 to 2 mm.
Claim 4
Dependent Claim
29 words
The method according to claim 1, wherein said pin comprises a metal having a high modulus of rigidity selected from the group consisting of hardened steel and tungsten alloys.
Claim 5
Dependent Claim
36 words
The method according to claim 1, comprising the additional step of forming a flange on said ferrule during said fluid resin introducing step, by providing a flange-forming mold portion adjacent said recess of said electroformed mold.
Claim 6
Dependent Claim
30 words
The method according to claim 1, wherein said pin has an enlarged portion remote from said end thereof, to prevent movement of said pin with respect to said electroformed mass.