This paper describes the optical characteristics and static fatigue reliability of a zirconia alignment sleeve, which is a component part of an optical connector with zirconia ferrules. This combination of sleeve and ferrules hardly generates any wear debris during connector insertion and removal cycles. This has reduced the cleaning frequency of the ferrule endface during cycles and greatly improved the return loss stability of the optical connectors. The zirconia alignment sleeve enables stable return loss characteristics to be achieved over a wide temperature range as it has the same thermal expansion coefficient as the zirconia ferrule. Furthermore, the gauge retention force for the zirconia alignment sleeve is defined with a view to its practical use. This force must be between 2.0 and 3.9 N to allow stable optical connections to be made under various mechanical and environmental conditions. We also clarify the conditions for a proof test by which to prevent the occurrence of static fatigue fractures in the sleeve, and we confirm the validity of the test. The static fatigue parameters for zirconia ceramics and derived from the static fatigue theory for brittle materials and fracture testing. We use these static fatigue parameters to predict the lifetime of a zirconia sleeve under working stress. An appropriate stress level for the proof test which eliminates weak sleeves, is about 3 times greater than working stress. The strength of the sleeve as demonstrated in the proof test is confirmed by accelerative stress aging. The performance of this sleeve is superior to that of a conventional copper alloy sleeve and the proof test confirms its reliability; under 0.1 FIT for 20 years of use.

Failure probability of a split ceramic alignment sleeve in an optical fiber connector has been predicted based on slow crack growth theory. Applying the theory to split zirconia ceramic alignment sleeves, a failure probability of 104 for 20 years is predicted and the value is expected to decrease to almost zero when an appropriate proof test is introduced.

This paper presents a design approach for developing MU-type single-mode miniature optical connectors featuring 1. 25 mm diameter zirconia ferrules. They are smaller and have a higher packaging density than conventional optical connectors. The ferrule pitch is 1/2, the plug volume 2/5 and the cross-sectional area 2/5 that of the SC connector. The aim of our approach is to reduce the ferrule size and to realize durable connectors. With 10/125 SM fibers, these MU connectors produced an average insertion loss of 0. 07 dB and an average return loss of 49. 4 dB, and there was no degradation during or after mechanical and environmental tests.

The statistical properties of insertion losses and return losses for optical connectors are investigated theoretically using the probability theory and the Monte Carlo simulation. Our investigation is focused on an orientation method for reducing insertion loss by which a fiber-core center is adjusted in a region of within a certain angle to the positioning key direction. It is demonstrated that the method can significantly improve insertion losses, and that an adjusting operation angle of 90 degrees is sufficient to realize an insertion loss of less than 0.5 dB with 99% cumulative probability. Good agreement was obtained between the theoretical distribution and the experimental results for single-mode fiber connection. Consequently, it is indicated that the statistical distributions of insertion losses and return losses of optical connectors in the field can be predicted theoretically from the values measured in the factory by connection to a master connector.