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CONNECTOR CHARACTERISTICS AND THEIR

IMPACT ON SYSTEM PERFORMANCE &
RELIABILITY
Telect, Inc.
2111 N. Molter Road, Liberty Lake, WA 99019
Tel 509-926-6000, 1-800-551-4567
Copyright 2000, Telect, I nc.
There are a large number of issues that affect the performance of fiber optic connectors in
todays networks. These factors are increasingly important as data rates, the number of
wavelengths, and transmission distances continue to escalate. The old analogy of a
system only being as strong as its weakest link is especially relevant today, and when
considering the amount of revenue being carried on each fiber an investment in a quality
connection is easily justified. This paper will discuss the issues that affect the fiber
connections reliability and performance. It begins with the impact of three key
connector components on a termination, followed by the importance of three measures of
ferrule geometry on short and long term performance, and finishes with the impact of
contaminants and defects on reliability.
Background
Fig. 1: Cross section of an interconnection
While there are several new technologies on the market for fiber optic connectors, the
vast majority of todays connectors utilize a cylindrical ferrule to capture the fiber. Each
ferrule is then aligned to another ferrule with a precision sleeve, as illustrated in Figure 1.
In order to ensure good contact, these ferrules are typically pressed together by means of
Spring: forces ends of the
fiber ferrule together
Ferrule ends make contact
and deform under load.
Cylindrical sleeve aligns
the mating ferrules.
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a spring housed inside the connector. The force from these springs is approximately 0.9
kg. However, because this force is applied over a very small area it causes deformation at
the end of the ferrule, even when rigid materials such as zirconia are used. This
deformation has the positive effect of compensating for imperfections in the shape of the
ferrule end. The result is that even if a termination contains some imperfections, a good
connection can still be achieved. More discussion of this phenomenon follows.
A. Component Impact on Fiber Connections
Ferrule
Ferrule Hole
Core
Fiber
Fig. 2: Effects of Component Eccentricity (Not to Scale)
1. Fiber and Ferrule
The main function of any connector/adapter is to align two ferrules, which in turn aligns
the two mating fibers. No matter how well this is accomplished there are other factors
working against good alignment, particularly eccentricities of the various components
(see Fig 2). Lack of concentricity in the ferrule is considered to be the leading
contributor to insertion loss, and the concentricity of the core to cladding of the fiber can
add to misalignment of the fiber cores. Because the core diameter is on the order of 8
microns, the effects of the ferrule hole or the fiber core being off center can have a large
effect on optical performance.
Performance issues are exacerbated if the hole diameter of the ferrule is larger than the
outside diameter of the fiber, a situation which causes the fiber to sit off to one side of
the hole. Nominal outside diameter for fiber is 125 um, but many cable assemblies are
manufactured using ferrules with 126 um or larger holes in order to ease the
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manufacturing process. This creates a crescent moon shaped gap on one side, and forces
the core away from center.
To minimize the effects of eccentricities, it is advisable to use reputable fiber
manufacturers and specify the use of ferrules with hole diameters of 125 microns.
2. Epoxy
The primary purpose of epoxy is to secure the fiber within the ferrule during polishing
and subsequently throughout the service life of the connector. The methods of curing
various types of epoxies are well known, but even after curing and polishing it is very
common for the fiber to move relative to the ferrule. (3) This is known as fiber pushback,
or pistoning of the fiber, and is caused by shear force from two main factors. The first
cause is normal force on the ferrule and fiber ends from the connector springs. The
second contributor is the inconsistent coefficient of thermal expansion between ferrules
and fiber.
Because ferrules are convex on the mating end face, the force from the spring is acting
only on the center portion of the ferrule, an area of approximately 225 microns after
deformation. The resulting normal forces in this area can approach 2,260 kg/cm^2. This
force manifests itself as shear force at the ferrule to fiber interface that the epoxy is
attempting to secure.
To combat this effect, recent studies have shown that the most important parameter of the
epoxy is its glass transition temperature, which correlates to its shear strength over
temperature. Studies conducted at Telect have shown that epoxies with a lower Tg may
experience fiber pistoning soon after termination when placed back in the curing oven for
a short time, even less than one minute. While this is an accelerated test, other studies
have shown that fiber pistoning or pushback occurs quite often in the first few hours of
deployment. (3)
Another important facet of epoxy is the presence of air bubbles introduced during mixing
and processing. When these bubbles are present the ferrule cavity only partially fills.
This can lead to inconsistent pressures being placed on the fiber that effect birefringence,
or possibly fracture the glass and cause failures. (1) For this reason it is important to
place the epoxy in a vacuum chamber prior to use so that these voids can be removed.
This process is called outgassing the epoxy and should be required of manufacturers
whose product is used in high reliability networks.
B. Polishing and Processing for Reliable Connections
The methods and results of polishing the fiber are really the measures that differentiate
one termination from the next. It was recognized some time ago that ferrules needed to
have a convex surface with the fiber at the apex to guarantee consistent results when
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mating fibers. The purpose of a convex surface is to ensure that when the ferrules came
together they will have glass to glass contact and avoid an air-gap (which causes higher
loss and higher backreflection). These are called Physical Contact or PC connectors, and
for these reasons essentially every ferrule today comes pre-radiused. There are variances
in the geometrical dimensions of these ferrules depending on vendor, but how one
accounts for, enhances, or overcomes these built in qualities determines the quality of the
fiber termination.
1. Endface Geometry
Telcordia (formerly Bellcore), as well as the EIA/TIA have published specifications on
what the end results should look like. These parameters are referred to as the Endface
Geometry of the connector. Numerous papers have been published that detail the
methods by which these specifications were arrived (2), as well as the impact of not
meeting them (typically involving Insertion Loss and Return Loss). As mentioned above,
it is imperative to maintain fiber to fiber contact if there is to be a reliable connection.
Following is a brief explanation of each parameter and its impact on the connection
Radius
R
Fig. 3: Radius of Curvature
Radius of Curvature
Radius of curvature specifies the magnitude of curvature on the end of the ferrule, as
measured by the radius of the arc describing the surface. For smaller values of R there
will be a smaller contact area, which concentrates the spring force of the connector into a
smaller area of the end face, resulting in increased deformation of the glass and ferrule.
This results in more stress on the fiber to ferrule interface (epoxy), increasing the
likelihood of fiber pushback. However, more deformation can also compensate for the
fiber being below the surface of the ferrule, called undercut (see Fiber Height below).
Conversely, larger values of R result in the end face being flatter, causing the contact area
of the ferrule to be larger and resulting in less deformation. The GR-326 Issue 3
recommendation is a Radius between 7 and 25 mm.
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Some studies have shown that the deformation can become plastic or permanent over
time when subjected to environmental stresses such as temperature and humidity (4).
Permanent deformation can result in inconsistent performance on subsequent matings,
but specifying zirconia ferrules from reputable manufacturers minimizes these effects.
Apex Offset
Fig. 4: Apex Offset
Apex Offset
Apex offset is a measure of how far off center the highest point of the convex end of the
ferrule is. It is important to minimize the offset so that the glass truly is at the highest
point of the ferrule end. Furthermore, because the offset can be in any direction, two
mated connectors can have offsets that are additive. Obviously, if the offset is too great,
core to core contact will not be achieved. The GR-326 Issue 3 recommendation is an
apex offset of less than 50 m.
5(a) 5(b)
Fig. 5(a) Undercut, and 5(b) Protrusion
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Fiber Height
In some ways the most important parameter of a fiber termination, the Fiber Height
specifies the position of the fiber surface relative to the surface of the ferrule. The ferrule
surface is measured one of two ways. 1) Spherical height - as if the surface were to
continue across the fiber hole in an arc of the same radius as the rest of the end face. 2)
Planar height - described by a straight line from one edge of the ferrule hole to the edge
on the opposite side. The former is more common.
Positive height is commonly termed protrusion, and a degree of protrusion typically aids
good fiber to fiber contact resulting in improved insertion loss performance. Excessive
protrusion can cause increased normal force to be exerted on the fiber, reducing the
durability of the connector in terms of mating cycles. In extreme cases excess fiber
height can cause a material fracture in the glass and a catastrophic failure to the link.
Negative height is typically termed undercut, and surprisingly a degree of undercut can
lead to improved return loss performance. It also improves connector performance in
terms of mating cycles and durability, although a small performance penalty is realized in
a higher insertion loss. When manufactured appropriately the deformation of the ferrule
compensates for the undercut position of the fiber so that fiber to fiber contact is still
achieved. Issue 2 of GR-326 mandated a fiber height of + /- 50 nm, but Issue 3 has
relaxed this requirement. The Issue 3 assumption is that a smaller radius will result in
increased deformation of the ferrule and compensate for higher degrees of undercut.
Accordingly the fiber height specification is now a function of the radius of the ferrule,
and allows as much as 125nm of undercut. One risk to this approach is that a reduced
spring force due to friction in the adapter sleeve can result in less normal force at the
ferrule interface. Additionally, connectors with large amounts of undercut are more
sensitive to the effects of fiber pushback. Studies have shown that excessive undercut
can cause return loss failures when subjected to temperature fluctuations. (#1) Because a
Fiber Height from 50 to +50 nm can be achieved in a controlled process, it is our
recommendation that this stricter specification is maintained.
2. Defects and Contaminants on the Endface
Specifications on defects and contaminants on the interface of a connection have been ill
defined and subjective at best. Typically, after the polishing process, a fiber is inspected
visually to check that no pits, scratches or blemishes appear in the core. Knowledgeable
manufacturers also check the inner portions of the cladding because a smaller amount of
light is also being transmitted in the inner portions of cladding. This combined area is
known as the Mode Field Diameter of the fiber and is a function of the fiber
manufacturing process.
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In a recent study, 60 cables from various manufacturers who are recognized leaders
within the industry were inspected. The results showed inconsistency in the monitoring
of surface defects, with some cables exhibiting no defects while others had defects in
critical areas. Examples of these are shown in Figures 6(a) and 6(b).
Fig 6(a) Fig 6(b)
Figs. 6(a) and 6(b) showing defects common in the industry.
Glass is a very brittle substance, and for this reason its strength is limited mainly by
material defects, be they internal or on the surface. Furthermore, defects in glass can
propagate. We all have experienced this when witnessing a crack in a vehicle windshield
increase in length until it has covered a great distance. An additional concern is that
under stress, silica bonds weaken in the presence of moisture (#1). To assure a quality
connection, it is important to eliminate defects and contaminants (especially moisture)
from the critical areas on the fiber endface. For example, Figure 7 below is a SEM photo
of a chip in a polished fiber endface that was small enough to be barely visible at 200x
magnification. One can see the potential for propagation of these defects over time,
especially when subjected to mechanical stress from the connector spring force,
temperature extremes, and in the presence of humidity.
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Fig. 7: SEM photo of a surface defect
It has been noted that ferrules deform when subjected to loads in the mated condition.
This results in contact being made over a fairly large region, approximately 225 m. For
these reasons it is wise to specify that no defects be present within this contact zone.
Not only could defects in the entire surface area of the fiber propagate over time due to
environmental stresses into the core of the fiber, but defects in the contact zone of the
ferrule can also act as reservoirs for contaminants. Likewise, a long scratch in this zone
can act as a capillary channel through which contaminants and moisture can migrate.
Two smooth surfaces brought in contact with each other will act as a barrier to
contaminants.
C. Conclusion
There is clearly a wide range of issues that effect the performance of a fiber patchcord or
pigtail termination. Unfortunately, typical end users do not have the time, equipment, or
expertise to inspect the cable assemblies that they purchase. Since no one has perfected
the fiber termination process, but instead must rely on yielded processes, the customers
are left with only two choices. Either make a large investment in time and equipment to
do the inspections themselves, or demand that their suppliers provide this service and
document the results. Nothing less than 100% inspection of all the critical termination
parameters can guarantee a reliable connection.
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References
1. William Wood et al., Bellcore; Reliability of Interconnection Devices, Proc. 9
th
Annual NFOEC, pgs. 209-221, 1993.
2. L.A. Reith, P.B. Grimado, J. Brickel, Bellcore; Effect of Ferrule-Endface Geometry
On Connector Intermateability, Proc. 11
th
Annual NFOEC, pgs. 635-646, 1995.
3. L.A. Reith et al.; Connector Materials Reliability In Hot, Humid Environments,
Bellcore, 1997 NFOEC Proceedings.
4. E. Makrides-Saravanos et al.; Creep Deformation of Zirconia Ceramic: Effect of
Composition and Sintering Temperature, 1998 NFOEC Proceedings.