Sleeve for optical connector ferrules and method for production thereof

Abstract

Disclosed are a sleeve for abutting, aligning, and retaining opposed optical connector ferrules and methods for the production thereof. The sleeve has a tubular body provided at three points on the inner wall surface thereof with ridges of an arcuate cross section extending from one to the other end of the tubular body in the longitudinal direction thereof and a slit formed therein in the longitudinal direction thereof. The sleeve is formed of an amorphous alloy possessing at least a glass transition region, preferably a glass transition region of not less than 30 K in temperature width. Preferably the sleeve is formed of an amorphous alloy having a composition represented by the following general formula and containing an amorphous phase in a volumetric ratio of at least 50%: X a M b Al c wherein X represents either or both of two elements, Zr and Hf, M represents at least one element selected from the group consisting of Mn, Fe, Co, Ni, and Cu, and a, b, and c represent such atomic percentages as respectively satisfy 25≦a≦85, 5≦b≦70, and 0<c≦35. Such a sleeve can be manufactured with high mass-producibility by a metal mold casting method or molding method.

What is claimed is:  
     
         1 . A sleeve for abutting, aligning, and retaining opposed optical connector ferrules, which sleeve is made of an amorphous alloy possessing at least a glass transition region.  
     
     
         2 . The sleeve according to    claim 1   , wherein said glass transition region has a temperature width of not less than 30 K.  
     
     
         3 . The sleeve according to    claim 1   , wherein said glass transition region has a temperature width of not less than 60 K.  
     
     
         4 . A sleeve for abutting, aligning, and retaining opposed optical connector ferrules, which sleeve is made of a substantially amorphous alloy having a composition represented by the following general formula and containing an amorphous phase in a volumetric ratio of at least 50%:  
       X a M b Al c   
       wherein X represents at least one element selected from the group consisting of Zr and Hf, M represents at least one element selected from the group consisting of Mn, Fe, Co, Ni, and Cu, and a, b, and c represent such atomic percentages as respectively satisfy 25≦a≦85, 5≦b≦70, and 0<c≦35.  
     
     
         5 . A sleeve for abutting, aligning, and retaining opposed optical connector ferrules, which sleeve is made of an amorphous alloy more susceptible of elastic deformation than the material for the optical connector ferrules.  
     
     
         6 . A sleeve for abutting, aligning, and retaining opposed optical connector ferrules, comprising a tubular body and three ridges provided on an inner wall surface of the tubular body, each of said ridges extending from one to the other end of the longitudinal direction of said tubular body and having an upper face assuming an arcuate cross section which curves toward an axis of said tubular body.  
     
     
         7 . The sleeve according to    claim 6   , wherein said tubular body has a slit formed throughout the entire length in the longitudinal direction thereof.  
     
     
         8 . The sleeve according to    claim 6   , wherein each of said ridges has a substantially semicircular cross section.  
     
     
         9 . The sleeve according to    claim 6   , wherein each of said ridges has a substantially semielliptic cross section.  
     
     
         10 . The sleeve according to    claim 6   , wherein each of said ridges has a triangular cross section containing a rounded upper end.  
     
     
         11 . The sleeve according to    claim 6   , wherein each of said ridges continuously or discontinuously extends the entire length of said tubular body.  
     
     
         12 . The sleeve according to    claim 6   , wherein each of said ridges has a height of 0.1 to 1.0 mm.  
     
     
         13 . The sleeve according to    claim 6   , wherein said sleeve is made of an amorphous alloy possessing a glass transition region of a temperature width of not less than 30 K.  
     
     
         14 . The sleeve according to    claim 6   , wherein said sleeve is made of a substantially amorphous alloy having a composition represented by the following general formula and containing an amorphous phase in a volumetric ratio of at least 50%:  
       X a M b Al c   
       wherein X represents at least one element selected from the group consisting of Zr and Hf, M represents at least one element selected from the group consisting of Mn, Fe, Co, Ni, and Cu, and a, b, and c represent such atomic percentages as respectively satisfy 25≦a≦85, 5≦b≦70, and 0<c ≦35.  
     
     
         15 . A method for the production of a sleeve for optical connector ferrules, comprising the steps of: 
 providing a melting vessel having an upper open end;    providing a forced cooling casting mold provided with at least one molding cavity and disposed above said melting vessel;    melting an alloying material capable of yielding an amorphous alloy in said melting vessel;    forcibly transferring the resultant molten alloy into the molding cavity of said forced cooling casting mold; and    rapidly solidifying said molten alloy in said forced cooling casting mold to confer amorphousness on the alloy thereby obtaining a cast product of an alloy containing an amorphous phase.    
     
     
         16 . The method according to    claim 15   , wherein said melting vessel has a molten metal transferring member disposed in the vessel and adapted to forcibly transfer the molten alloy upward, and said forced cooling casting mold is provided with at least two identically shaped molding cavities and runners communicating with said cavities, said runners being disposed on an extended line of a transfer line for the molten metal transferring member.  
     
     
         17 . The method according to    claim 16   , wherein said molten metal transferring member is caused to transfer forcibly the molten alloy in said melting vessel into the molding cavities of said forced cooling casting mold and meanwhile exert pressure on said molten alloy filling the molding cavities of said forced cooling casting mold.  
     
     
         18 . The method according to    claim 15   , wherein said forced cooling casting mold is a water-cooled casting mold or gas-cooled casting mold.  
     
     
         19 . The method according to    claim 15   , wherein said alloying material has a composition represented by the following general formula and is endowed with an ability to yield a substantially amorphous alloy containing an amorphous phase in a volumetric ratio of at least 50%:  
       X a M b Al c   
       wherein X represents at least one element selected from the group consisting of Zr and Hf, M represents at least one element selected from the group consisting of Mn, Fe, Co, Ni, and Cu, and a, b, and c represent such atomic percentages as respectively satisfy 25≦a≦85, 5≦b≦70, and 0<c≦35.  
     
     
         20 . The method according to    claim 15   , wherein said melting of said alloying material in said melting vessel is carried out in a vacuum or under an atmosphere of inert gas.  
     
     
         21 . A method for the production of a sleeve for optical connector ferrules, comprising the steps of: 
 providing a vessel for melting an alloying material capable of producing an amorphous alloy possessing a glass transition region, said vessel being provided with a hole and retaining a melt of said alloying material;    providing a metal mold provided with a sprue and at least one cavity of the shape of a product aimed at;    connecting said hole formed in said vessel to the sprue of said metal mold;    applying pressure on said melt in the vessel to introduce a prescribed amount of said melt via the hole of said vessel into said metal mold thereby filling said cavity with said melt; and    solidifying said melt in said metal mold at a cooling rate of not less than 10 K/s to obtain a product of an alloy containing an amorphous phase.    
     
     
         22 . The method according to    claim 21   , wherein said alloying material has a composition represented by the following general formula and endowed with an ability to yield a substantially amorphous alloy containing an amorphous phase in a volumetric ratio of at least 50%:  
       X a M b Al c   
       wherein X represents at least one element selected from the group consisting of Zr and Hf, M represents at least one element selected from the group consisting of Mn, Fe, Co, Ni, and Cu, and a, b, and c represent such atomic percentages as respectively satisfy 25≦a≦85, 5≦b≦70, and 0<c≦35.  
     
     
         23 . A method for the production of a sleeve for optical connector ferrules, comprising the steps of: 
 heating an amorphous material formed of an alloy represented by the following general formula and containing an amorphous phase in a volumetric ratio of at least 50% to a temperature in a supercooled liquid region:    X a M b Al c     wherein X represents at least one element selected from the group consisting of Zr and Hf, M represents at least one element selected from the group consisting of Mn, Fe, Co, Ni, and Cu, and a, b, and c represent such atomic percentages as respectively satisfy 25≦a≦85, 5≦b≦70, and 0<c≦35;    inserting the resultant hot amorphous material in a container held at the same temperature;    connecting a metal mold provided with a cavity of the shape of a product aimed at to said container; and    introducing a prescribed amount of said alloy under pressure into said metal mold by virtue of the viscous flow of said supercooled liquid to form a sleeve.