The field of the present invention relates to connectors for optical fibers. In particular, apparatus and methods are described herein for securing a fiber ferrule within a connector assembly.
A wide variety of connector assemblies are available for connecting optical fibers. Some of these are described in:
Many varieties of connector assemblies exist for end-to-end coupling of optical fibers. Types of connectors include, but are not limited to, Avio (Avim), ADT-UNI, Biconic, D4, Deutsch 1000, DIN (LSA), DMI, E-2000 aka LSH, EC, ESCON, F07, F-3000, FC, Fibergate, FSMA, LC, ELIO, Lucxis, LX-5, MIC, MPO/MTP, MT, MT-RJ, MU, NEC D4, Opti-Jack, OPTIMATE, SC, SMA, SMC, ST/BFOC, TOSLINK, VF-45, 1053 HDTV, and V-PIN. LC and SC connectors currently are the most common commercially available connector assemblies. A common feature of many of the exemplary connector assemblies is an end of an optical fiber held in a fiber ferrule. The present disclosure or appended claims shall be construed as encompassing any connector for optical fiber employing a fiber ferrule.
The ferrule typically comprises a substantially cylindrical member with an axial bore for receiving the end of the optical fiber. The ferrule is formed from ceramic, metal, or certain polymers or plastics; the material employed is preferably substantially rigid and dimensionally stable. The axial bore is substantially concentric with respect to the ferrule outer surface; the precision required for that concentricity is dictated by the precision required for relative transverse positioning of the coupled optical fibers to achieve sufficiently small insertion loss for the fiber connection. The diameter of the axial bore is selected to accommodate the optical fiber while positioning it sufficiently precisely relative to the ferrule outer surface (again, to achieve sufficiently small insertion loss). The fiber typically is secured within the bore with epoxy or other suitable adhesive. Ferrules that are only partly cylindrical (e.g., that include a flange, notch, slot, or similar structural feature) or non-cylindrical also fall within the scope of the present disclosure or appended claims.
The end of the ferrule and the end of the fiber secured within it are typically polished together so that the end of the fiber is flush with an end surface of the ferrule. Various connection geometries are employed wherein the end of the ferrule, and the end of the fiber polished with it, are flat, slightly convex, substantially perpendicular to the ferrule axis, or slightly tilted relative to the ferrule axis (e.g., by about 8°). Air-gap or physical-contact arrangements can be employed for optically coupling two fibers end-to-end. Physical contact between the fiber ends reduces insertion loss and back reflection from the fiber connection; convex ferrule surfaces enable more reliable physical contact between the fiber ends. Index-matching gels or liquids are sometimes employed in an air-gap or physical contact arrangement to reduce insertion loss and back reflection. Angling the fiber end faces further reduces back reflection. All of those arrangements fall within the scope of the present disclosure or appended claims.
To achieve end-to-end coupling of two optical fibers 110/210, each fiber end is received (and polished) within a corresponding ferrule 120/220 as described above (
In any of the exemplary fiber connector arrangements shown or described, the fibers 110/210 and corresponding ferrules 120/220 are attached to or held by the corresponding connector assemblies 150/250, which include corresponding connector body members 140/240. The ferrules 120/220 can be secured to the corresponding body members 140/240 in a variety of ways depending on the specific structure or construction of the connector assemblies 150/250. In some examples the ferrules 120/220 are movable relative to the corresponding body members 140/240 to facilitate mating of the connector assemblies 150/250 or alignment of the ferrules 120/220; in such examples the ferrules 120/220 can be spring-loaded or otherwise biased to facilitate or maintain such mating or alignment. In other examples the ferrules 120/220 can be substantially rigidly attached to or held by the corresponding body members 140/240. In various examples, an interference, friction, or press fit arrangement can be employed to substantially rigidly hold the ferrules 120/220. In other examples an adhesive or a retainer can be employed. In any of those examples, it is typically desired that the ferrules 120/220 remain secured to the corresponding body members 140/240 during typical use conditions, including if or when the connector assemblies 150/250 are pulled apart.
In one conventional exemplary arrangement of an optical fiber connector assembly (
It may be desirable in some circumstances to employ a connector assembly 450 in which a channel for receiving the ferrule 420 is formed in a unitary body member 440 of the connector assembly 450 (as in
It is therefore desirable to provide an optical fiber connector assembly in which a ferrule is received within a channel formed in a unitary body portion of the connector assembly, and in which flowing adhesive can be deployed to adequately fill aligned slots or grooves on the ferrule and body without depositing unwanted adhesive on the surface or one or both ends of the ferrule.
A connector assembly for an optical fiber comprises a unitary connector body and a fiber ferrule. The unitary connector body has (i) an integrally formed axial ferrule channel formed therethrough and (ii) an integrally formed transverse passage connecting the ferrule channel and an outer surface of the connector body. The fiber ferrule is positioned at least partly within the ferrule channel, and has (i) an axial fiber channel formed therethrough and (ii) a transverse ferrule groove on an outer surface thereof. The fiber ferrule is positioned so that a volume defined by the ferrule groove and a surface of the ferrule channel communicates with the transverse passage. The connector assembly can further comprise a retaining member positioned at least partly within the ferrule groove and at least partly within the transverse passage. The retaining member comprises hardened material that had flowed, prior to hardening, (i) through the transverse passage into the ferrule groove and (ii) into the transverse passage.
Objects and advantages pertaining to connector assemblies for optical fibers may become apparent upon referring to the exemplary embodiments illustrated in the drawings and disclosed in the following written description or appended claims.
This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
It should be noted that the embodiments depicted in this disclosure are shown only schematically, and that not all features may be shown in full detail or in proper proportion. Certain features or structures may be exaggerated relative to others for clarity. It should be noted further that the embodiments shown are exemplary only, and should not be construed as limiting the scope of the written description or appended claims.
The connector assembly 550 can further comprise a retaining member 560 positioned at least partly within the ferrule groove 522 and at least partly within the transverse passage 544. The retaining member 560 comprises (i) hardened material that had flowed, prior to hardening, through the transverse passage 544 into the ferrule groove 522 and (ii) hardened material that had flowed, prior to hardening, into the transverse passage 544. The hardened material can comprise, e.g., cured polymer of any suitable type (e.g., epoxy adhesive, liquid in its uncured state), reflowed polymer of any suitable type, reflowed solder of any suitable type, reflowed glass of any suitable type, or fused glass frit or any suitable type. “Any suitable type” denotes materials that, upon hardening, are sufficiently rigid for the retaining member 560 to retain the ferrule 520 within the connector body 540 under typically use conditions, and that have properties and processing requirements that are compatible with materials of the ferrule 520, the connector body 540, or other elements of the connector assembly 550.
The arrangements of
A method for making the connector assembly 550 comprises: (a) positioning the fiber ferrule 520 at least partly within the ferrule channel formed through the unitary connector body 540; (b) flowing material (i) into the transverse passage 544 and (ii) through the transverse passage 544 into the ferrule groove 522; and (c) after flowing the material, allowing or causing the flowed material to harden to form a retaining member 560 positioned at least partly within the ferrule groove 522 and at least partly within the transverse passage 544. Allowing or causing the material to harden can include, e.g., heat or ultraviolet curing of a polymer, or cooling of reflowed or fused material.
In some embodiments (e.g.,
In some embodiments, the unitary connector body 540 has an integrally formed transverse channel groove 542 on the ferrule channel surface (as in
In embodiments that include a channel groove 542 (as in
Another exemplary embodiment is illustrated schematically in
The exemplary connector assemblies of
The exemplary connector assemblies of
The exemplary connector assemblies of
In addition to the preceding, the following examples also fall within the scope of the present disclosure or appended claims:
A connector assembly for an optical fiber, the connector assembly comprising: a unitary connector body having (i) an integrally formed axial ferrule channel formed therethrough and (ii) an integrally formed transverse passage connecting the ferrule channel and an outer surface of the connector body; and a fiber ferrule positioned at least partly within the ferrule channel, said ferrule having (i) an axial fiber channel formed therethrough and (ii) a transverse ferrule groove on an outer surface thereof, wherein the fiber ferrule is positioned so that a volume defined by the ferrule groove and a surface of the ferrule channel communicates with the transverse passage.
The connector assembly of Example 1 further comprising a retaining member positioned at least partly within the ferrule groove and at least partly within the transverse passage, wherein said retaining member comprises (i) hardened material that had flowed, prior to hardening, through the transverse passage into the ferrule groove and (ii) hardened material that had flowed, prior to hardening, into the transverse passage.
The connector assembly of Example 2 wherein the ferrule groove extends only partly around a transverse perimeter of the ferrule, so that the retaining member limits rotation of the ferrule within the ferrule channel about an axis parallel to the axial fiber channel.
The connector assembly of Example 1 wherein the unitary body has an integrally formed transverse channel groove on the ferrule channel surface positioned so that a volume defined by the channel groove and a surface of the ferrule communicates with the volume defined by the ferrule groove and the surface of the ferrule channel.
The connector assembly of Example 4 wherein the volume defined by the channel groove and a surface of the ferrule communicates with the transverse passage.
The connector assembly of any one of Examples 4 or 5 further comprising a retaining member positioned at least partly within the ferrule groove and at least partly within the channel groove, wherein said retaining member comprises hardened material that had flowed, prior to hardening, through the transverse passage into the ferrule groove and into the channel groove.
The connector assembly of Example 6 wherein the ferrule groove extends only partly around a transverse perimeter of the ferrule or the channel groove extends only partly around a transverse perimeter of the ferrule channel, so that the retaining member limits rotation of the ferrule within the ferrule channel about an axis parallel to the axial fiber channel.
The connector assembly of any one of Examples 2, 3, 6, or 7 wherein the hardened material comprises cured polymer, reflowed polymer, reflowed solder, reflowed glass, or fused glass frit.
The connector assembly of any one of Examples 1 through 8 further comprising a ferrule sleeve attached to the unitary body in a substantially coaxial arrangement with the fiber ferrule.
The connector assembly of Example 9 wherein at least a portion of the fiber ferrule is positioned within the ferrule sleeve and at least a portion of the ferrule sleeve is not occupied by the fiber ferrule.
The connector assembly of any one of Examples 1 through 10 further comprising an optical fiber positioned within the fiber channel.
The connector assembly of any one of claims 1 through 11 further comprising a housing attached to or integrally formed with the unitary body.
The connector assembly of any one of Examples 1 through 12 further comprising a connecting member attached to or integrally formed with the unitary body, said connecting member being arranged to engage and retain a mating connector component or assembly.
A method for making a connector assembly for an optical fiber, the method comprising positioning a fiber ferrule at least partly within a ferrule channel formed through a unitary connector body, wherein: the unitary connector body has (i) the integrally formed axial ferrule channel formed therethrough and (ii) an integrally formed transverse passage connecting the ferrule channel and an outer surface of the connector body; the fiber ferrule has (i) an axial fiber channel formed therethrough and (ii) a transverse ferrule groove on an outer surface thereof; and the fiber ferrule is positioned so that a volume defined by the ferrule groove and a surface of the ferrule channel communicates with the transverse passage.
The method of Example 14 further comprising: flowing material (i) into the transverse passage and (ii) through the transverse passage into the ferrule groove; and after flowing the material, allowing or causing the flowed material to harden to form a retaining member positioned at least partly within the ferrule groove and at least partly within the transverse passage.
The method of Example 15 wherein the ferrule groove extends only partly around a transverse perimeter of the ferrule, so that the retaining member limits rotation of the ferrule within the ferrule channel about an axis parallel to the axial fiber channel.
The method of Example 14 wherein the unitary body has an integrally formed transverse channel groove on the ferrule channel surface positioned so that a volume defined by the channel groove and a surface of the ferrule communicates with the volume defined by the ferrule groove and the surface of the ferrule channel.
The method of Example 17 wherein the volume defined by the channel groove and a surface of the ferrule communicates with the transverse passage.
The method of any one of Examples 17 or 18 further comprising: flowing material through the transverse passage into the ferrule groove and the channel groove; and after flowing the material, allowing or causing the flowed material to harden to form a retaining member positioned at least partly within the ferrule groove and at least partly within the channel groove.
The method of Example 19 wherein the ferrule groove extends only partly around a transverse perimeter of the ferrule or the channel groove extends only partly around a transverse perimeter of the ferrule channel, so that the retaining member limits rotation of the ferrule within the ferrule channel about an axis parallel to the axial fiber channel.
The method of any one of Examples 15, 16, 19, or 20 wherein the hardened material comprises cured polymer, reflowed polymer, reflowed solder, reflowed glass, or fused glass frit.
The method of any one of Examples 14 through 21 further comprising attaching a ferrule sleeve to the unitary body in a substantially coaxial arrangement with the fiber ferrule.
The method of Example 22 wherein at least a portion of the fiber ferrule is positioned within the ferrule sleeve and at least a portion of the ferrule sleeve is not occupied by the fiber ferrule.
The method of any one of Examples 14 through 23 further comprising positioning an optical fiber within the fiber channel.
The method of any one of Examples 14 through 24 further comprising attaching a housing to, or integrally forming a housing with, the unitary body.
The method of any one of Examples 14 through 25 further comprising attaching a connecting member to, or integrally forming a connecting member with, the unitary body, said connecting member being arranged to engage and retain a mating connector component or assembly.
A method for making a connector assembly for an optical fiber, the method comprising forming through a unitary connector body (i) an integrally formed axial ferrule channel and (ii) an integrally formed transverse passage connecting the ferrule channel and an outer surface of the connector body, the channel and the passage being arranged so that with a fiber ferrule positioned at least partly within the ferrule channel, said ferrule having (i) an axial fiber channel formed therethrough and (ii) a transverse ferrule groove on an outer surface thereof, a volume defined by the ferrule groove and a surface of the ferrule channel communicates with the transverse passage.
The method of Example 27 further comprising forming the transverse ferrule groove on the fiber ferrule.
The method of any one of Examples 27 or 28 wherein the ferrule groove extends only partly around a transverse perimeter of the ferrule.
The method of any one of Examples 27, 28, or 29 further comprising forming a transverse channel groove on the ferrule channel surface of the unitary body, the channel groove and the ferrule groove being arranged so that with the fiber ferrule positioned at least partly within the ferrule channel a volume defined by the channel groove and a surface of the ferrule communicates with the volume defined by the ferrule groove and the surface of the ferrule channel.
The method of Example 30 wherein the channel groove and the ferrule groove are arranged so that with the fiber ferrule positioned at least partly within the ferrule channel the volume defined by the channel groove and a surface of the ferrule communicates with the transverse passage.
The method of any one of Examples 30 or 31 wherein the ferrule groove extends only partly around a transverse perimeter of the ferrule or the channel groove extends only partly around a transverse perimeter of the ferrule channel.
The method of any one of Examples 27 through 32 further comprising attaching a housing to, or integrally forming a housing with, the unitary body.
The method of any one of Examples 27 through 33 further comprising attaching a connecting member to, or integrally forming a connecting member with, the unitary body, said connecting member being arranged to engage and retain a mating connector component or assembly.
It is intended that equivalents of the disclosed exemplary embodiments and methods shall fall within the scope of the present disclosure or appended claims. It is intended that the disclosed exemplary embodiments and methods, and equivalents thereof, may be modified while remaining within the scope of the present disclosure or appended claims.
In the foregoing Detailed Description, various features may be grouped together in several exemplary embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that any claimed embodiment requires more features than are expressly recited in the corresponding claim. Rather, as the appended claims reflect, inventive subject matter may lie in less than all features of a single disclosed exemplary embodiment. Thus, the appended claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate disclosed embodiment. However, the present disclosure and appended claims shall also be construed as implicitly disclosing any embodiment having any suitable set of one or more disclosed or claimed features (i.e., sets of features that are not incompatible or mutually exclusive) that appear in the present disclosure or the appended claims, including those sets that may not be explicitly disclosed herein. It should be further noted that the scope of the appended claims do not necessarily encompass the whole of the subject matter disclosed herein.
For purposes of the present disclosure and appended claims, the conjunction “or” is to be construed inclusively (e.g., “a dog or a cat” would be interpreted as “a dog, or a cat, or both”; e.g., “a dog, a cat, or a mouse” would be interpreted as “a dog, or a cat, or a mouse, or any two, or all three”), unless: (i) it is explicitly stated otherwise, e.g., by use of “either . . . or,” “only one of,” or similar language; or (ii) two or more of the listed alternatives are mutually exclusive within the particular context, in which case “or” would encompass only those combinations involving non-mutually-exclusive alternatives. For purposes of the present disclosure and appended claims, the words “comprising,” “including,” “having,” and variants thereof, wherever they appear, shall be construed as open ended terminology, with the same meaning as if the phrase “at least” were appended after each instance thereof.
In the appended claims, if the provisions of 35 USC § 112 ¶6 are desired to be invoked in an apparatus claim, then the word “means” will appear in that apparatus claim. If those provisions are desired to be invoked in a method claim, the words “a step for” will appear in that method claim. Conversely, if the words “means” or “a step for” do not appear in a claim, then the provisions of 35 USC §112 ¶6 are not intended to be invoked for that claim.
The Abstract is provided as required as an aid to those searching for specific subject matter within the patent literature. However, the Abstract is not intended to imply that any elements, features, or limitations recited therein are necessarily encompassed by any particular claim. The scope of subject matter encompassed by each claim shall be determined by the recitation of only that claim.
This application claims benefit of U.S. provisional App. No. 61/609,361 filed Mar. 11, 2012 in the name of Rolf A. Wyss, said provisional application being hereby incorporated by reference as if fully set forth herein.
Number | Date | Country | |
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61609361 | Mar 2012 | US |