Technical Report 648

SManufacturing Technology ProgramFIBER OPTIC MULTIPIN HYBRID CONNECTOR

RA.GM HolmaRAGreenwell

17 December 1980

Final Report for Period November 1977 to March 1980

A Prepared for

Naval Air Systems Command.NAVAIR 360G

M C*n MTSUJLHD TO DflC Cr1C:TLWO A

Approved for public release; distribution unlimited

NAVAL OCEAN SYSTEMS CENTERI+ SAN DIEGO, CALIFORNIA 92152

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NAVAL OCEAN SYSTEMS CENTER, SAN DIEGO, CA 92152

AN ACTIVITY OF THE NAVAL MATERIAL COMMAN D

SL GUILLE, CAPT, USN HL BLOODCommuider Technical Director

ADMINISTRATIVE INFORMATION

Work was performed under Program Element 63728N, Subproject ZI050-SL (NOSC73 1-ETi 5) by the Amphenol RF Division of Bunker Ramo Corporation per contract

.P(N66001-78-C-O034)under the cognizance of the Electronics Design Branch (NOSC Code5 9242), for Naval Air Systems Command, NAVAIR 360G. This report covers work from

November 1977 to March 1980 and was approved for publication 17 December 1980.

Released by Under authority ofCL Ward, Head PC Fletcher, HeadDesign Engineering Electrouics Engineering

Division and Sciences Department

METRIC CONVERSION

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UNCLASSIFIEDSECURITY, CLASSIFICATIONOF THIS PAGE ('When Data Entered) -

REPORT DOCUMENTATION PAGE BEFORE COMPLE FORM.REPORT NUMBER 2 GOVT ACCESSION NO. . RE I S CATALOG NUMBER

NOSC Technical Report 648 (TR 648) - 9 ' f 5 7

TITLE (and subtitle) Co 01P O -

Manufactring Technology Program . Fial I__ L~,.,. FIBER OPTIC MULTIPIN HYBRID CONNECTOR 9. Nov A,1T77*MardlI P A

7. AUTHOR(AN S.EONTPACT OR GRANT NUMBER(S

=2eeweli9.PRFORMING ORGANIZATION NAME AND ADDRESS PRGA-JCT, TASK

II.PEORA AREA 6W9K UIT NU 4ERSNaval Ocean Systems Center PE 63728N/.Ii50W-SLSan Diego, CA 92152 (NOSC 73 1-ET5)1-

'I. CONTROLLING OFFICE NAME AND ADDRESSNaval Air Systems Command 17~. Decft OWNAVAIR 360G N'.NUMBER OFPVMAc S j/,/,"

Washington DC 2036110 ( T14. MONITORING AGENC'"R #ta O rCtf.d,.satenm.Cegeu.ane Office) IS. SECURITY CLASS (of t

"4" Unclassified

s. DECLASSI FCATION/ DOWNGRADINGSCHEDULE

16. DISTRIBUTION STATEMENT (of this Report)

Approved for public release; distribution unlimited

17. DISTRIBUTION STATEMENT (of the abstroct entered In Block 20, If different from Report)

II. SUPPLEMENTARY NOTES

19. KEY WORDS (Continue on reverse oide If n'cessary and Identify by block number)

Fiber opticsConnectors !A

20. ABSTRACT (Continue on reverse side itf necessary and Identify by block number)

A hybrid fiber optic and electrical multipin connector was developed for bundle type (0.045 inch bundle diameter)fiber optic cable. This task was performed under the Manufacturing Technology Program for fiber optic components.The connector was built by means of high volume production techniques and was tested for suitability to theii military environment.

DD , jA.73 1473 EDIT,ON OF I NOV 65 IS OBSOLETE UNCLASSIFIEDS/N 0102- LF. 014- 6601 SECURITY CLASSIFICATION OF THIS PAGE (When Date Ant ord')

UNCLASSIFIEDSECURITY CLASSIFICAION4 OF THIS5 PAGE (Whumn Date 3Iff.,.*

1

S/N 002*L~o146601UNCLASSIFIED

SECURITY CLASSIFICATION OF THIS PAC(Whmen Date Entered)

Develop and document fiber optic component manufacturing processes to allowdistribution of manufacturing information among second sources and to provide low cost,high volume production capabilities in industry for fiber optic components suitable for use in

a military environment.

RESULTS

1. A hybrid multipin fiber optic connector for bundle cable (0.045 inch diameter

glass bundle) was successfully built and tested.

2. The connector was built by means of high volume production machinery. A costanalysis shows a cost reduction of 73% for production runs.

3. The connector passes the environmental specifications of MIL-C-26482. Failuresduring testing resulted from fiber optic cable problems.

4. Fiber optic cable is the limiting factor in high temperature performance of thecable-connector

interface.

5. Full documentation is available for the manufacturing of these connectors.

I ! RECOMMENDATIONS

1. Standardize cinnectors and cables to guarantee compatibility between

2. Develop single-fiber multipin connectors for 125 and 140 pm cable based on thesame approach - a standard electrical pin shell with fiber optic contacts replacing the elec-trical contacts.

5ut i i cat o-'-'--

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INTRODUCTION

The goal of the fiber optic manufacturing technology program is to develop anddocument fiber optic component manufacturing processes. This allows the distribution ofmanufacturing information among second sources and provides low cost, high volume pro-duction capabilities in industry for fiber optic components. These components are designedspecifically for their application to high volume, low cost production, and for their ability topass the environmental specifications of MIL-C-26482.

I n November 1977, a contract was awarded to Bunker Ramo Corporation (Affinhenol)fQr the.development of a multipin fiber op .onne.cjoqr. The connector was to incorporateboth wire contacts, for power, and fiber optic bundle contacts, for short cable runs (less than50 metres).

PROGRAM PLAN

The contract was performed in three phases. Phase I consisted of developing the de-sign and manufacturing processes for a quantity of 10 connectors. These connectors weimexposed to limited testing. Phase II consisted of manufacturing a production run of 100connector pairs. Phase III consisted of testing to evaluate the ability of the connectors topass the environmental specifications of MIL-C-26482. The documentation consisted ofa fabrication specification, engineering drawings, a cost analysis, and a test specificationand report. The engineering drawings are contained in the appendix. The fabricationspecification and the test specification and report are available to both industry andDoD agencies; contact the Manufacturing Technology Office, NOSC Code 9204.

The cost analysis is available to DoD agencies only.

PRODUCT FABRICATION SPECIFICATION

The Product Fabrication Specification includes a list of the operations necessary forproduction, the assembly instructions, and the stages at which inspection is performed. Asindicated in the engineering drawings, the connector manufacturing process uses standardmachining techniques. The connector shell is a standard Amphenol/Merlin series 118MIL-C-26482G connector, available off the shelf. 'The fiber optc contacts, both male andfemale, use a crimp/epoxy combination for attachment of the caule strength members. Theoutside dimensions of the fiber optic contacts and size 12 electrical contacts are similar.The fiber optic contacts are aligned by a Delrin alignment sleeve, when the plug and recep-tacle are mated. This provides for a typical optical loss of 3 dB for bundle cables. Duringtests, the typical loss measured was 3-5 dB, due to a mismatch between the cable bundlediameter and the contact hole size. The fiber opti, glass bundle size used in tests was too

*' small, resulting in a large packing fraction loss in initial connector insertion. Loss measure-ments using cable with a better packing fraction and smaller numerical aperture (0.61 and0.65) resulted in losses of 2.43 and 3.16 dB respectively during Phase I testing.

COST ANALYSIS

An analysis was done on the manufacturing cost of the connectors. A cost compari-f: son was made between the 10 prototype connectors built in the model shop and the pro-duction rn of 100 mating pairs done in the production facility. Estimates were extrapolated

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. to the production cost of 1000 mating pairs. The analysis included the costs of material, Aproduction setup, handling and processing, and assembly. The unit cost in quantities of

100 mating pairs was 34% of the unit cost of 10 manufactured in the model shop. The unit

cost of 1000 mating pairs was 27% of the model shop cost.

TEST REPORT

The production/acceptance Inspection Test Report describes the testing performed

under this contract. The tests follow the general pattern of MIL-C-26482G connector tests,

with the added requirement of monitoring the increase of connector loss after each test. An

arbitrary I dB increase was established as the amount of acceptable degradation after each

test. The testing sequence is shown in table 1, with all tests referenced to MIL-C-26482G.Table 2 summarizes the test results. Summation of the testing showed that each of Bunker

Ramo's fiber optic connectors and contacts was capable of meeting the mechanical, electri-cal, and/or environmental requirements specified in the test procedure.

Failures occurred during the testing sequence. The faults that existed in the testresults reflect optical discrepancies directly related to cable shrinkage at elevated tem-peratures. These deficiencies took place under thermal shock (-550 to 125'C) and fluidimmersion at 85°C.

Analysis of failed test specimens revealed two modes of failure with similar character-istics; both resulted from shrinkage of the cable at elevated temperatures.

One mode of failure is shrinkage of the cable out of the crimped contact ferruleassembly. The result is mechanical failure of the unsupported optical fibers in the con-tact during subsequent testing. This specific failure is resolved by applying epoxy to the

strength members prior to crimping the ferrule. The epoxy is then cured subsequent to thecrimp, Corrective action in this mode has been made by modifying the termination procedureto include this operation. The termination procedure is included with the enclosed drawings.

The second mode of failure results from fixing the strength member as describedabove. Shrinkage results in random crushing and fracture of the fibers throughout the cablelength. ,legt.The fiber optic cable used in the Phase III testing program did not meet the original

specification, as outlined in NOSC Technical Report 274 (ref 1).;t It has been verified that the initial cable developed under the specification contained

in reference I did meet the environmental requirements of the Production/Acceptance TestProcedure. The difference between the cables is that the original contained braided strengthmembers whereas the cable used in Phase III testing contained straight strength members (not

g ! braided or woven). Phase IIi cable was not rejected, however, because of the long lead timein obtaining replacement.

in

1. NOSC TR 274, Manufacturing Technology for Fiber Optic Bundle Cabling, by GM Holma andRA Greenwell, 10 July 1978.

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SUMMARY OF RESULTS

The connector developed was Aniphenol's 801 series multichannel bundle connector.The design consisted of adapting fiber optic bundle contacts to have the same external di-mensions as an existing electrical contact for a multipin electrical connector. This wasaccomplished with a size 12 fiber optic contact, which fit into an unmodified MIL-C-26482Gmultipin electrical connector shell. This approach was compatible with the desired goal ofthe program. The connector shell was an already approved, tested MIL-SPEC componentwith off-the-shelf availability. The contacts can be !::ass-produced on automatic screw ma-chines. This same principle was used in Amphenol's 801 series single fiber connector. Thestrength member attachment had to be designed so as not to interfere with the scheme for

optical contact retention, which was identical to that for electrical contact retention. Theconnector can accommodate any combination of a total of eight wire or fiber optic bundlec n t acts in a 0quiAc k- d is conn e ct, -sIz-_e 18Q sh1ell, MIL -C- 2641 G series 2, class L, fluid resistant

connector. The connector developed under their contract met all the initially establishedrequirements.

Failures that occurred during tests were attributed to the fact that the fiber opticcable jacket and strength members did not meet the originally specified temperature ex-tremes of -55' to 150'C. The connector design in MIL-C-26482G has a top temperatureof 2000 C. Although tests were limited to 125'C because of the cable limitations, shrinkageof the cable jacket and strength members resulted in failures during the fluid immersions andtemperature shock tests. Procurement of fiber optic cable which meets the original cablespecifications as listed in reference 1 would eliminate these failures.

RECOMMENDATIONS

1. Standardize connectors and cables to guarantee compatibility between

components.2. Develop single-fiber multipin connectors for 125 and 140 tam cable based on the

same approach - a standard electrical pin shell with fiber optic contacts replacing the elec-

trical contacts.

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1. Cable Preparation

1.1 Remove outer jacket for a length of 1h". CAUTION: Do not cut orremove Kevlar strengthening fibers.

OUTERJACET

1.2 Draw strength fibers back over outer jacket. Remove 1.34" of innercable jacket to expose the optical fibers. (Remove serving threadthat is wrapping the fibers.) Be careful not to break any of theoptical fibers. . - .

IWNE -- IFIBER BUNDLE

OUTE.R JACKET --- /STRENGTH FIE5 _ I

1.3 Clean the exposed fiber bundle and 1 to 2 inches under the jacket byeither dipping the cable and in liquid Freon TF or by spraying thefibers with spray Freon TF. CAUTION: Do not breathe vapors.

1.4 Mix the epoxy per the manufacturer's instructions (recommended epoxyis EPO-TEK 353 N.D. mixed 100 parts of resin and 10 parts of catalyst

by weight.)

1.5 Bundle strength fibers together and lay parallel to glass fiberbundle. Carefully slip ferrule over both and slide onto cable up toapprox. 3/8" from the outer jacket of fiber optic cable.

1.6 Apply epoxy sparingly to exposed strength members and slide ferruleover epoxied area to abut with the outer jacket of fiber optic cable.

1.7 Separate strength fibers from glass fiber bundle and draw in directionof ferrule from exposed glass fibers.

1.8 Apply a drop of epoxy to the glass fiber bundle and work into bundleto cause epoxy to cover the surfaces of the fibers for a distance upto within "of the inner jacket.

AMPHENOL NORTH AMERICA Bunker Rao Corpor,, iono i, Coffci,.t,' ""'" 'CODE IDENT, SPECIFICATION N&, ' 1

UNLESS OTHERWISE SPECIFIED ~ ~ SEIIAINN ~JDIMENSIONS ARE IN INCMES: 4AND TOLERANCES ARE' C

FRACTIONS DECIMALS • ANGLES _ ___ O

- SCALE' sHET

1.9 Slip contact onto glass fiber bundle until it butts against the crimpferrule. Draw strength fibers tight, keep contact in place againstferrule. Place assembly into crimping tool (Handle Aphenol #227-444,Die Set Amphenol #227-909-2022) and register contact collar in recessprbvided for it. Check for maintaining positioning of contact ferruleand that strength fibers are held tight. Close handle of crimp toolaffecting crimping of the ferrule. Put one drop of epoxy on fiberswhere they project through nose of contact.

1.10 Place crimped assembly under a source of beat and cure epoxy at atemperature of 1200 C for 15 minutes minimum. When epoxy on fibers atnose of contact turns red, the epoxy is cured. Care should be exer-cised so that curing temperatuce is not exceeded or cable jacket will bedamaged.NOTE: Red epoxy should also be evident at back of crimped ferrule onstrength members if properly assembled.

1.11 Allow assembly to cool to room temperature.

2. Polishing Prm,-' o~e

2.1 Snap r.!-; excess fibers that project from end of contact.

2.2 Insert contact into polishing tool.Use Tool #227-909-2021 for socket contact (801-999-5124).and Tool #227-909-2020 for receptacle contact (801-999-5125).

2.3 Polish using 60 micron polishing film; bring fibers to within .010"of contact tip. Polish using water as a lubricant and coolant.

2.4 Using successively finer polishing film, repeat process until fibersare brought into plaa of end of contact and no further material isremoved. The final polishing step should be accomplished using 1 micronpolishing film.

2.5 Dry and examine under 50% magnification for gross imperfections. Besure the optical surface is flat and free of scratches, chips or epoxysmears.

1 EPO-TEK 353 N.D. Epoxy Technology, Inc.65 Grove Street

~tWatertown, Mass. 02172

1 Imperial Lapping Film Sheets

3M CompanySt. Paul, Minn. 55101

2.6 Remove strength fibers from front end of ferrule (cut flush with razorblade). Inspect retention collar area of contact. Be certain that anystray epoxy is removed from the surfaces. (See following page forillustration.)

A AMPHENOL NORTH AMERICA Bunker Rino Corporation a Danbury, Connecti

UNLESS O'rHERISE SPECIFIED COI soENT. SPECIFICATION .mDIMENSIONS ARE IN INCHES:AND TOLERANCES ARE'

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CAUTION: if procedure described in 2.6 is not adhered to duringterminating a fiber optic cable, the contact retention system ofthe connector will be damaged and the contact will fail to remaincaptivated.

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