Low-loss small-size optical-fiber connector with a precision plastic-molded ferrule

This paper describes a newly developed low-loss small-size optical connector for single-coated fibers. The structural design for reducing the connector size has been studied. On the basis of the design, a connector composed of four components per plug, with a diameter of 3.5 mm and a length of 40 mm, has been constructed. In addition, a precise plastic-ferrule-molding technique has been investigated. It has been found that the eccentricity error of the manufactured ferrule is less than 1 μm. The fabricated connectors have shown average connection losses of 0.11 dB for multimode fibers and 0.25 dB for single-mode fibers. Mechanical and heat-cycle test results are satisfactory for the practical use of the connector.