Manufacturing method for high precision mold

Details Manufacturing method for high precision mold Manufacturing method for high precision mold

1999-11-23

2001-10-30

Sells, James (Department: 1734)

Adhesive bonding and miscellaneous chemical manufacture

Methods

Surface bonding and/or assembly therefor

C156S150000, C156S242000

Reexamination Certificate

active

06309488

ABSTRACT:

BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to a manufacturing method for a high precision mold and to a manufacturing method for a multi-fiber ferrule by combining different parts of the multi-fiber ferrule made from molds.
2. Related Art
As the science progresses, a large amount of information has to be transmitted among people via internet. An optical fiber (fiber) has been chosen as a better transmission medium for the information. However, due to the limitation of the fiber, separated sectors will exist between fibers. The fiber connector (ferrule) is then used to connect these separated sectors.
FIG. 1
shows a conventional multi-fiber connector, which is used to make a continuous braid type multi-fiber network and comprises a connector sleeve
1
made into a single body and a fixing element
2
. The connector sleeve
1
is provided with a plurality of fiber aligning apertures and two pin aligning apertures for aligning pins. The errors on the diameter of each fiber aligning aperture and the span between the fiber aligning apertures are required to be within 1 &mgr;m.
The U.S. Pat. No. 5,786,002 “Guide block assembly for aligning bore forming pins during molding of multi-fiber optical connector ferrules” provides an assembly made of single-piece polished separate guide elements as the mold of a molding fiber sleeve. As shown in
FIG. 2
, the mold disclosed by this patent comprises a plurality of closely placed guide elements
22
with fiber aligning apertures provided thereon, pin aligning guide elements
24
with pin aligning apertures formed thereon and disposed on both sides of the closely placed guide elements
22
, and elements
26
a
,
26
a
formed on the top and bottom surfaces of the closely placed guide elements
22
for supporting.
However, the above method requires high precision polishing on each guide element
22
, the pin aligning guide elements
24
, and the elements
26
a
,
26
b
before combining them together into the mold. This is not only expensive in cost but also not practical for mass production.
SUMMARY OF THE INVENTION
In viewing of the foregoing problems, it is an object of the present invention to provide manufacturing method for a high precision mold.
It is another object of the present invention to provide a manufacturing method for a separate type fiber connector sleeve.
The instant invention provides a manufacturing method for a high precision mold, which comprises the steps of providing a plastic body on a conductor substrate; forming a plurality of perforating apertures in the plastic body using X-ray deep etching molding (LIGA technology); forming a rounded edge at the front end of the perforating apertures in the plastic body using ultraviolet (UV) lithography, and electroforming the high precision mold using the plastic body with perforating apertures as the model.
The present invention also provides a manufacturing method for a fiber connector sleeve, which comprises the steps of forming a fiber aligning element using a high precision mold by ejection or by heat pressing, forming a fiber sleeve body using a usual mold by ejection or by heat pressing, and combining the fiber aligning element with the fiber sleeve body using ultrasonic waves to form the fiber connector sleeve.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.


REFERENCES:
patent: 5269998 (1993-12-01), Takagi et al.
patent: 5389312 (1995-02-01), Lebby et al.
patent: 5482451 (1996-01-01), Johnson et al.
patent: 5786002 (1998-07-01), Dean et al.
patent: 6071442 (2000-06-01), Dean et al.
patent: 6074577 (2000-06-01), Katsura et al.

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