U.S. patent application number 15/630861 was filed with the patent office on 2018-05-10 for foldover optical fiber ferrule assembly.
The applicant listed for this patent is NANOPRECISION PRODUCTS, INC.. Invention is credited to Gregory L. KLOTZ, Shuhe LI, Robert Ryan VALLANCE.
Application Number | 20180128990 15/630861 |
Document ID | / |
Family ID | 51453837 |
Filed Date | 2018-05-10 |
United States Patent
Application |
20180128990 |
Kind Code |
A1 |
LI; Shuhe ; et al. |
May 10, 2018 |
FOLDOVER OPTICAL FIBER FERRULE ASSEMBLY
Abstract
A ferrule assembly for an optical fiber connector has a first
ferrule component having a structured surface defining features for
aligning a section of an optical fiber, and a second ferrule
component that is coupled to the first ferrule component by a web,
wherein the web is flexible to allow folding the web to fold the
second ferrule component over the groove in the first ferrule
component. The optical alignment features includes one or more open
grooves for receiving a bare section of an optical fiber. The
section of the optical fiber is retained in the groove between the
two ferrule components.
Inventors: |
LI; Shuhe; (Pasadena,
CA) ; VALLANCE; Robert Ryan; (Newbury Park, CA)
; KLOTZ; Gregory L.; (La Verne, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NANOPRECISION PRODUCTS, INC. |
El Segundo |
CA |
US |
|
|
Family ID: |
51453837 |
Appl. No.: |
15/630861 |
Filed: |
June 22, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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14449133 |
Jul 31, 2014 |
9690054 |
|
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15630861 |
|
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|
61860863 |
Jul 31, 2013 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G02B 6/3838 20130101;
G02B 6/3839 20130101; Y10T 29/4984 20150115; G02B 6/3858 20130101;
G02B 6/3826 20130101; Y10T 29/49 20150115; G02B 6/3885
20130101 |
International
Class: |
G02B 6/38 20060101
G02B006/38 |
Claims
1. A ferrule assembly for supporting an optical fiber in an optical
fiber connector, comprising: a first ferrule component having a
first body; a second ferrule component having a second body; an
optical alignment feature or an optical fiber is defined in at
least one of the first body and second body; and a web connecting
the second ferrule to the first ferrule, wherein the web is
flexible to allow folding of the second ferrule component over the
first ferrule component, wherein the optical fiber is held between
opposing sides of the first ferrule component and the second
ferrule component in a folded over configuration.
2. The ferrule assembly as in claim 1, wherein the first ferrule
component has a first edge and the second ferrule component has a
second edge adjacent to the first edge, and wherein the web is
connected to the first edge and the second edge.
3. The ferrule assembly as in claim 2, wherein the first ferrule
component, the second ferrule component and the web are part of a
monolithic structure.
4. The ferrule assembly as in claim 1, wherein the optical
alignment feature comprises a feature defining at least a groove in
the first body which is sized to support a section of the optical
fiber.
5. The ferrule assembly as in claim 4, wherein the groove is
structured to securely retain the section of optical fiber in the
groove by clamping the optical fiber.
6. The ferrule assembly as in claim 5, wherein the groove is an
open groove structured to support terminating end sections of the
optical fiber, wherein the terminating section of the optical fiber
is bare, with cladding exposed.
7. The ferrule assembly as in claim 6, wherein at least one of the
first body and the second body is structured with a recess for
receiving at least part of a protective layer of the optical
fiber.
8. The ferrule assembly as in claim 1, wherein the optical
alignment feature comprises a feature defining at least a first
groove in the first body and at least a second groove in the second
body, wherein the first and second grooves together support a
section of the optical fiber.
9. The ferrule assembly as in claim 4, wherein first body comprises
a feature defining a plurality of pin grooves on the surface of the
first body, wherein each pin groove has a longitudinal opening, and
wherein each groove is sized and shaped to securely retain an
alignment pin in the groove by clamping the alignment pin.
10. The ferrule assembly as in claim 4, wherein the optical
alignment feature is structured to support an array of optical
fibers.
11. The ferrule assembly as in claim 10, wherein the optical
alignment feature comprises a feature defining a plurality of
grooves, each sized to support a section of a respective optical
fiber.
12. The ferrule assembly as in claim 1, wherein the web has a
reduced thickness compared to thickness of the first ferrule
component and the second ferrule component.
13. The ferrule assembly as in claim 4, wherein the second body is
structured with a flat surface at the side opposing the first
ferrule component, and wherein the flat surface faces the groove on
the first body.
14. The ferrule assembly as in claim 1, wherein the first ferrule
component and the second ferrule component are maintained in the
folded over configuration by a fastening mechanism.
15. The ferrule assembly as in claim 14, wherein the latch
mechanism comprises a snap coupling based on features defined on
the first and second ferrule components.
16. An optical fiber connector, comprising: a ferrule assembly as
claimed in claim 1; and a housing supporting the ferrule.
17. A method of producing a ferrule assembly as in claim 1,
comprising forming at least the first body having the groove from a
blank.
18. A method of producing a ferrule assembly for supporting an
optical fiber in an optical fiber connector, comprising: forming a
first ferrule component having a first body structured with an
optical alignment feature for the optical fiber; forming a second
ferrule component having a second body; and forming a web
connecting the second ferrule to the first ferrule, wherein the web
is flexible to allow folding of the second ferrule component over
the first ferrule component, wherein the optical fiber is held
between opposing sides of the first ferrule component and the
second ferrule component.
19. The method of producing a ferrule assembly as in claim 18
wherein the first ferrule component, the second ferrule component
and the web are formed from a same blank.
20. The method as in claim 19, wherein the first ferrule component,
the second ferrule component and the web are part of a monolithic
structure formed by stamping the same blank.
Description
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 14/449,133 filed on Jul. 31, 2014, which
claims the priority of U.S. Provisional Patent Application No.
61/860,863 filed on Jul. 31, 2013, which are fully incorporated by
reference as if fully set forth herein. All publications noted
below are fully incorporated by reference as if fully set forth
herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] The present invention relates to optical fiber connectors,
in particular ferrules in optical fiber connectors.
2. Description of Related Art
[0003] There are many advantages of transmitting light signal via
optical fiber waveguides and the use thereof is diverse. Optical
signal transmission requires coupling of optical fibers in an
end-to-end relationship, with the coupling being one source of
light loss. In an optical fiber connection, an optical fiber
connector terminates the end of a cable that contains one or
multiple fibers, and enables quicker connection and disconnection
than splicing to another connector holding the end of another
cable. The connectors mechanically couple and align the cores of
fibers so that light can pass end-to-end. Better connectors lose
very little light due to reflection or misalignment of the fibers.
Connectors, in both parallel/multiple fiber and single fiber links,
operating at multi-gigabit rates must be assembled with
subcomponents fabricated with sub-micron precision (i.e., a
tolerance of less than 1000 nm). As if producing parts with such
precision levels were not challenging enough, for the resulting end
product to be economical it must be done in a fully automated, very
high-speed process.
[0004] Currently, it is generally accepted that current fiber
connectors cost too much to manufacture and the reliability and
loss characteristics are more to be desired. The tolerance of the
fiber connectors must improve, and the cost of producing fiber
connectors must decrease if fiber optics is to be the communication
media of choice for short haul and very short reach applications.
The relatively widespread and ever increasing utilization of
optical fibers in communication systems, data processing and other
signal transmission systems has created a demand for satisfactory
and efficient means of inter-joining fiber terminals.
[0005] U.S. Pat. No. 7,311,449, commonly assigned to the
assignee-applicant of the present invention, discloses various
embodiments of ferrules that can be mass produced cost effectively
by stamping. Some of those ferrules are configured for optical
alignment without using alignment pins, relying solely on the
alignment sleeves to provide alignment of the precisely shaped
ferrules.
[0006] U.S. patent applicant Ser. No. 13/861,375 (published as
counterpart WO 2014/011283), and U.S. patent application Ser. No.
13/440,970 (Published as US2012/0257860A1), which are commonly
assigned to the assignee of the present invention, disclose
improved ferrule and sleeve designs that can be incorporated in new
optical fiber connectors, which results in low insertion loss and
low return loss, which provides ease of use and high reliability
with low environmental sensitivity, and which can be fabricated at
low cost. In particular, U.S. patent application Ser. No.
13/440,970 discloses a ferrule having an open structure that has
precision features formed thereon, namely open fiber clamping
grooves, which can securely clamp the optical fibers without the
need for epoxy or a complementary precision part. The width of the
longitudinal opening defined between the lips along at least a
section of the grooves is narrower than the diameter of the optical
fibers to create a tight fit (e.g., an interference fit) with
respect to the fibers, which allows the terminating end section of
an optical fiber to be inserted laterally into the longitudinal
opening of the groove, but which snuggly retains the optical fiber
in the groove.
[0007] The present invention provides further improvements in
ferrule designs, which provide ease of use and high reliability,
and which can be fabricated at low cost.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] For a fuller understanding of the nature and advantages of
the invention, as well as the preferred mode of use, reference
should be made to the following detailed description read in
conjunction with the accompanying drawings. In the following
drawings, like reference numerals designate like or similar parts
throughout the drawings.
[0009] FIG. 1A illustrates a perspective view of a foldover optical
fiber ferrule assembly in an open position in accordance with one
embodiment of the present invention; FIG. 1B illustrates the
ferrule assembly in a slightly folded position; FIG. 1C illustrates
the ferrule assembly in a closed or completely folded position;
FIG. 1D is a sectional view taken along line 1D-1D in FIG. 1C; FIG.
1E is a sectional view taken along line 1E-1E in FIG. 1D.
[0010] FIG. 2 is a perspective view of a foldover optical fiber
ferrule assembly in a closed position in accordance with another
embodiment of the present invention.
[0011] FIG. 3 is a perspective view of a foldover optical fiber
ferrule assembly in a closed position in accordance with a further
embodiment of the present invention.
[0012] FIG. 4A is a perspective view of a foldover optical fiber
ferrule assembly in an open position in accordance with another
embodiment of the present invention; FIG. 4B illustrates the
ferrule assembly in a closed or completely folded position; FIG. 4C
is a sectional view taken along line 4C-4C in FIG. 4B.
[0013] FIG. 5 illustrates an optical fiber connector incorporating
the inventive foldover optical fiber ferrule assembly.
SUMMARY OF THE INVENTION
[0014] The present invention provides a ferrule assembly for an
optical fiber connector, which improves on current ferrules. The
ferrule assembly in accordance with the present invention provides
ease of use and high reliability, and it can be fabricated at low
cost.
[0015] In one aspect of the present invention, the ferrule assembly
comprises a first ferrule component and a second ferrule component
that is coupled to the first ferrule component by a web or tether
of reduced thickness, wherein the web is flexible to allow folding
the web to fold the second ferrule component over the groove in the
first ferrule component. An optical alignment feature is defined on
at least one of the first ferrule component and the second ferrule
component for optical alignment (e.g., aligning a section of an
optical fiber). At least one of the first ferrule component and the
second ferrule component is provided with a structured surface
defining features for optical alignment, In one embodiment, the
optical alignment features include one or more open grooves for
receiving a section of an optical fiber (e.g., the terminating end
section of an optical fiber). The section of the optical fiber is
retained in the groove between the two ferrule components.
[0016] In one embodiment, the optical alignment feature is defined
in the first ferrule component, comprising a groove having a
longitudinal opening, which is sized to receive and securely retain
a section of an optical fiber in the groove by clamping the section
of the optical fiber. The second ferrule component is a plate,
which when folded over the groove in the first ferrule component,
opposes and covers the groove in the first ferrule component.
[0017] In a further embodiment, the alignment feature includes
similar grooves provided in the first ferrule component for
receiving an alignment guide pin.
[0018] In another embodiment of the present invention, the first
ferrule component and the second ferrule component may be
structured as two complementary ferrule halves, each with a
complementary groove that together retain the section of an optical
fiber and/or an alignment guide pin.
[0019] In another aspect of the present invention, the ferrule
assembly is precision formed by high throughput processes, such as
stamping and extrusion. In one embodiment, at least the first
ferrule component is formed by stamping to define the geometries of
its external body and groove. In another embodiment, the entire
ferrule assembly is formed by stamping to define the geometries of
the first ferrule component, the second ferrule component and the
interconnecting web.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] This invention is described below in reference to various
embodiments with reference to the figures. While this invention is
described in terms of the best mode for achieving this invention's
objectives, it will be appreciated by those skilled in the art that
variations may be accomplished in view of these teachings without
deviating from the spirit or scope of the invention.
[0021] The ferrule in accordance with the present invention further
improves the current ferrule designs, which can be incorporated in
an optical fiber connector to result in low insertion loss and low
return loss, and which provides ease of use and high reliability
with low environmental sensitivity, and which can be fabricated at
low cost.
[0022] In one aspect of the present invention, the ferrule assembly
comprises a first ferrule component and a second ferrule component
that is coupled to the first ferrule component by a web or tether
of reduced thickness, wherein the web is flexible to allow folding
the web to fold the second ferrule component over the groove in the
first ferrule component. An optical alignment feature is defined on
at least one of the first ferrule component and the second ferrule
component for optical alignment (e.g., aligning a section of an
optical fiber). At least one of the first ferrule component and the
second ferrule component is provided with a structured surface
defining features for optical alignment, In one embodiment, the
optical alignment features include one or more open grooves for
receiving a section of an optical fiber (e.g., the terminating end
section of an optical fiber). The section of the optical fiber is
retained in the groove between the two ferrule components.
[0023] In one embodiment of the present invention, the ferrule
assembly comprises a first ferrule component having a structured
surface defining features for optical alignment (e.g., aligning a
section of an optical fiber), and a second ferrule component that
is coupled to the first ferrule component by a web or tether of
reduced thickness (as compared to the thickness of the first and
second ferrule components), wherein the web is flexible to allow
folding the web to fold the second ferrule component over the
groove in the first ferrule component.
[0024] In one embodiment, the optical alignment features includes
one or more open grooves for receiving a section of an optical
fiber (e.g., the terminating end section of an optical fiber). The
section of the optical fiber is retained in the groove between the
two ferrule components.
[0025] FIG. 1A illustrates a perspective view of a foldover optical
fiber ferrule assembly 10 in accordance with one embodiment of the
present invention. The ferrule assembly 10 is shown in its opened
or unfolded position. It comprises a first ferrule component 12 and
a second ferrule component 14 interconnected by strips of thin webs
16 extending between adjacent edges of the first and second ferrule
components 12 and 14. The thickness of the webs 16 are
significantly less than the thickness of the first and second
ferrule components 12 and 14, to be flexible and bendable. The webs
16 and the first and second ferrule components 12 and 14 may be an
integral, monolithic and/or unitary structure (i.e., a continuum
without any connection interfacing surface structure; e.g., formed
by die casting, etching, molding, powder metallurgy/sintering, or
stamping from a single piece of stock material or blank), or may be
separate pieces of same or different materials (e.g., made by die
casting, etching, molding, powder metallurgy/sintering, or
stamping) which are attached together (e.g., by welding, epoxy,
rivets, etc.). Alternatively, the web 16 may be formed by molding a
plastic over the first and second ferrule components 12 and 14, by
a process generally known as over-molding.
[0026] In one embodiment, the first and second ferrule components
12 and 14 are each generally in the shape of a plate, with surface
features defined on at least the opposing sides (22, 24) between
the first and second components 12 and 14 (when they are in a
folded over position shown in FIG. 1C). In the opened unfolded
position shown in FIG. 1A, the surface features are defined on the
same side of the overall ferrule assembly 10. The webs 16 extend
between the sides 22 and 24 of the first and second ferrule
components 12 and 14. In the illustrated embodiment, the webs 16
are parallel, spaced thin narrow strips, bridging a continuous
surface between sides 22 and 24. Instead of two webs as shown, a
single strip of web may be provided, or more than two strips of web
may be provided.
[0027] The optical alignment feature defined at one side 22 (e.g.,
a major planar surface) of the body of the first ferrule component
12 comprises at least a groove 18 having a longitudinal opening,
which is sized to receive and securely retain a section of an
optical fiber 20 in the groove 18 by clamping the section of the
optical fiber 20. In the illustrated embodiment, the groove 18 is
sized to receive the terminating end section of the optical fibers
20 (bare sections of the optical fibers 20, with cladding exposed,
without protective buffer and jacket layers). The structure of the
grooves 18 will be elaborated further below. In the embodiment
illustrated in FIG. 1A, there are a plurality of grooves 18
provided at the surface section 23 of the side 22 near one edge of
the first ferrule component 12, which receive the bare terminating
end sections of an array of optical fibers 20 from a fiber cable
(e.g., a flat ribbon 30 shown in FIG. 1B). Further, a shallow
recess 32 is defined on the side 22, to provide a space to receive
the sleeve 31 of the fiber ribbon 30 (i.e., the protective fiber
cable jacket) (see also FIG. 1B). Part of a section of the sleeve
31 of the fiber ribbon 30 is received within the recess 32, which
provides additional room to accommodate the thickness of the sleeve
31 and the protective buffer and jacket layers on the fibers 20
within the section of the sleeve 31 received in the recess 32.
[0028] In this embodiment, the surface feature defined on the side
24 of the body of the second ferrule component 14 is a matching
shallow recess 34, to provide a space to receive the remaining part
of the section of the sleeve 31 of the fiber ribbon 30 received in
the recess 34. However, in this embodiment, the side 24 of the
second ferrule component 14 is not provided with grooves for
optical fibers. The matching/mating surface 25 on the side 24 near
one edge of the second ferrule component 14 is flat, acting to
cover the grooves 18 on the first ferrule component 12 when the
second ferrule component 14 is folded over to oppose the groove in
the first ferrule component 12 (see also FIGS. 1B and 1C). The
second ferrule component 14 includes raised flanges 26 along its
opposing side edges.
[0029] FIG. 1B illustrates the ferrule assembly in a slightly
folded position. In this configuration, it resembles an open
"clamshell" structure. Each thin web 16 is bent from its plane, to
form a fold 17 along each strip of web 16. Depending on the
thickness of the thin strip of web 16, one or more scribe lines may
be provided to facilitate bending/folding of the web.
Alternatively, certain sections of the web 16 may be thinned (e.g.,
at the section of the strip of web 16 between the attachment points
to the first and second ferrule components 12 and 14) to facilitate
bending of the web 16.
[0030] FIG. 1C illustrates the ferrule assembly in a closed or
completely folded position, with a view from the underside of the
first ferrule component 12. FIG. 1D is a sectional view taken along
line 1D-1D in the folded position shown in FIG. 1C. FIG. 1E is a
sectional view taken along line 1E-1E in FIG. 1D. In this position,
the second ferrule component 14 is completely folded over the first
ferrule component 12, with the sides 22 and 24 of the first and
second ferrule components 12 and 14 in opposing relationship, and
in mating relationship other than at the recesses 32 and 34 and at
the grooves 18. In this configuration, it resembles a closed
"clamshell" structure. The section of fiber ribbon sleeve 31 is
retained within the opposing recesses 32 and 34. The raised flanges
26 on the second ferrule component 14 are fitted over and mated
against opposing side edges of first ferrule component 12,
preferably by means of an interference fit or snap fit, to form a
fastening/latching means to securely keep the first and second
ferrule components 12 and 14 in the folded over position shown in
FIGS. 1C-1E. Referring to the view shown in FIG. 1D, a slight draft
angle may be provided on the opposing side walls of the first
ferrule component (i.e., a taper diverging towards the second
ferrule component 14) and a complementary taper of the flange 26 on
the second ferrule component (diverging towards the first ferrule
component 12) provide a snap coupling of the first and second
ferrule components 12 and 14. Further, scribe lines may be provided
on the web 16 at or near the attachment points to facilitate
removing the web 16 from the first and second ferrule components 12
and 14 after folding the second ferrule component 14 over the first
ferrule component 12 to the closed position shown in FIG. 1C. In
this embodiment, the snap coupling is based on features defined on
the first and second ferrule components 12 and 14.
[0031] In one aspect of the present invention, the first ferrule
component 12 has an open structure that has precision features
formed thereon, namely open fiber clamping grooves, which can
securely clamp the optical fibers without the need for epoxy or a
complementary precision part. The grooves and the width of the
longitudinal groove openings are shaped and sized to retain the
fibers without any clearance to allow for movement of the optical
fibers 20 relative to the groove 18. In one embodiment, the first
ferrule component 12 has a body having a plurality of open grooves
18 formed in parallel on one surface thereof for receiving and
clamping the terminating end sections of optical fibers. The
grooves 18 are structured to securely retain the fibers 20 (bare
sections with cladding exposed, without protective buffer and
jacket layers) by clamping the fibers 20, e.g., by an interference
fit (or press fit). As referenced throughout herein, in the context
of the present invention, and consistent with the customary usage
in the mechanical field, the term "interference" refers to the
dimensional relationship between mating parts, which is beyond the
dimensional tolerances of individual parts. Tolerance is an
intended limit to dimensional variations or deviations from a
nominal dimension in connection with the fabrication of a part by a
controlled process. The actual dimension would be within the
tolerance range about the nominal dimension. In contrast,
interference is achieved by intentionally sizing and shaping at
least one of two mating parts with intended nominal dimensions to
provide the desired interference fit between the two mating parts.
There would be fabrication tolerances for the nominal dimensions
that are intended to achieve the intended interference. In other
words, even if there is zero tolerance in the fabrication process,
the actual dimensions would then be the nominal dimensions of the
mating parts, which would still result in the interference as
intended. The interference fit assures that the fibers 20 are
clamped in place and consequently the position and orientation of
the fibers is set by the location and parallelism of the grooves
18.
[0032] In one embodiment as illustrated in FIG. 1D, the grooves 18
in the body of the first ferrule component 12 may be generally
U-shaped channels each having approximately parallel walls
extending from a semicircular bottom. The distance between the
parallel walls of a groove 18 is sized to be slightly less than the
diameter of the optical fiber 20 (bare fiber with cladding exposed,
without protective buffer and jacket layers) to provide
interference fit. (As referenced throughout herein, the diameter of
the optical fibers refers to the diameter of the bare fiber with
cladding exposed without protective buffer and jacket layers, e.g.,
125 .mu.m.) This interference fit alone can be sufficient to
securely clamp the ends of the fibers 20 within the grooves 18.
[0033] In another embodiment, at least a section of the
longitudinal opening of the groove is provided with opposing lips
to provide a clamping effect. The width of the longitudinal opening
defined between the lips/edges of the grooves 18 is made slightly
narrower than the diameter of the bare sections of the optical
fibers 20 to create a tight interference fit to snuggly retain the
optical fibers 20. In particular, the opening is defined by lips
formed at the opposing longitudinal edges of the longitudinal
opening, to be slightly under-sized to allow the terminating end
section of the optical fibers to be inserted laterally into the
longitudinal openings of the grooves 18 with an interference fit.
The magnitude of interference can be set by the manufacturing
process so that loading the fiber into the groove causes elastic
deformation or minor plastic deformation in the lip. The grooves
should not be plastically deformed, otherwise it will affect the
accuracy of the fiber locations.
[0034] Specifically, to attach the fibers 20 to the first ferrule
component 12, the terminating end section of the fibers 20 are
pressed lengthwise into the grooves 18 through the longitudinal
openings with a snap action (i.e., not in the axial direction of
the grooves), with the tip of the fibers 20 slightly protruding
beyond the end face of the ferrule component body. Further, the
width of the longitudinal openings and the grooves 18 are sized and
shaped to snuggly retain the section of optical fibers 20 in the
grooves 18 without providing any clearance for axial and lateral
movements of the end face of the fibers relative to the grooves to
ensure tight tolerance for optical coupling between end faces of
two adjoining fibers. No epoxy would be required for retaining the
bare fiber sections in the grooves given the interference along the
mating surfaces between the fibers 20 and the grooves 18.
[0035] It is noted that the contact pressure resulting from the
interference between the groove and fiber should not exceed the
strength of the fiber. It should only be great enough to retain the
fiber and generate friction that opposes axial sliding motion of
the fibers within the grooves. Only a few micrometers of
interference is necessary. In general, the interference is less
than a few micrometers, more typically one or two micrometers.
[0036] It is noted that given the grooves 18 provides precise
alignment of the optical fibers 20 with respect to the first
ferrule component 12, the second ferrule component 14 does not need
to be formed with as high tolerance as the first ferrule component
12. Given that lateral spacing of the optical fiber 20 are defined
entirely by the grooves 18 in the first ferrule component 12, the
second ferrule component 14 does not contribute to defining the
lateral spacing of the optical fiber 20.
[0037] While the grooves 18 in the above-described embodiments are
sized to self-retain by clamping the terminating bare sections of
the optical fibers, the grooves 18 may be formed to retain the
terminating end sections of the optical fibers 20 without clamping
such sections (e.g., not self-retaining). The grooves 18 may be
formed with a close tolerance (without interference fit) in
U-shaped or deep V-shaped in the first ferrule component 12, and
rely on the opposing surface 25 of the second ferrule component 14
to cover the grooves to tightly retain the bare section of the
optical fibers 20 in the grooves. The grooves would still provide
alignment of the lateral spacing of the optical fibers.
[0038] While the embodiment of FIG. 1 provides grooves 18 only on
the first ferrule component 12, it is contemplated that in an
alternate embodiment, complementary half-grooves (e.g., grooves of
semi-circular and/or V-shaped cross-section) may be provided on
opposing sides 23 and 25 of the first and second ferrule components
12 and 14, to form a complete closed groove to securely retain the
terminating end sections of optical fibers 20 (bare sections of the
optical fibers 20, with cladding exposed, without protective buffer
and jacket layers). See also embodiment of FIG. 2 discussed
below.
[0039] While in the illustrated embodiments, latches by means of
flanges 26 are provided only on the second ferrule component 14, it
is contemplated that raised flanges may be provided instead on the
first ferrule component 12 to fit over the edges of the second
ferrule component 14, or raised flanges may be provided partially
on the first and second ferrule components 12 and 14. Other means
of fastening or latching may be implemented, including external
clips to keep the first and second ferrule components 12 and 14 in
the closed position.
[0040] Still further, while the webs 16 are illustrated to be
provided at the adjacent end or back edges (perpendicular to the
longitudinal direction of the fiber ribbon 30) of the first and
second ferrule components, it is contemplated that the webs may be
provided along adjacent lateral side edges (parallel to the
longitudinal direction of the fiber ribbon 30) of the first and
second ferrule components 12 and 14.
[0041] It can be seen that the one-piece ferrule assembly in its
closed position forms a ferrule for optical fibers. The one-piece
design facilitates ease of use to affix the end sections of an
array of optical fibers of a fiber ribbon to a ferrule (in this
case a ferrule formed by a ferrule assembly in accordance with the
present invention).
[0042] FIGS. 2 and 3 illustrate further embodiments of ferrule
assemblies. In a further embodiment of the present invention, the
first ferrule component and the second ferrule component may be two
complementary ferrule halves, each with a complementary groove that
together retain the section of an optical fiber and/or an alignment
guide pin. In particular, FIG. 2 is a perspective view of a
foldover optical fiber ferrule assembly 110 in a closed position in
accordance with another embodiment of the present invention. In
this embodiment, the first and second ferrule components 112 and
114 of the ferrule assembly 110 are externally shaped with an
overall generally oval cross-section. The geometry of the ferrule
components have been disclosed in U.S. patent applicant Ser. No.
13/861,375 (published as counterpart WO 2014/011283). In accordance
with the present invention, webs 116 are provided at the adjacent
end or back edges of the first and second ferrule components 112
and 114, in similar manner as the web 16 in the previous embodiment
shown in FIG. 1A. In this embodiment, each of the first and second
ferrule components 112 and 114 are provided with open half grooves
118, which combine to form a round closed groove to retain the bare
termination section of the optical fibers 20. Other than the
grooves 118 and external surface profile of the first and second
ferrule components 112 and 114 in this embodiment, the surface
features of the opposing sides of the first and second ferrule
components 112 and 114 may be similar to those of the ferrule
assembly 10 in the previous embodiment shown in FIG. 1A. For
example, recesses (not shown) are provided at the opposing sides of
the first and second ferrule components 112 and 114 to define a
space to receive the sleeve 31 of the fiber ribbon 30. Raised
flanges 126 may also be provided along the lateral edges of the
first and second ferrule components 112 and 114.
[0043] In a further embodiment, the alignment feature includes
similar grooves provided in the first ferrule component for
receiving an alignment guide pin. FIG. 3 is a perspective view of a
foldover optical fiber ferrule assembly 210 in a closed position in
accordance with a further embodiment of the present invention. In
this embodiment, the first and second ferrule components 212 and
214 of the ferrule assembly 210 are externally shaped similar to
the embodiment of FIG. 1A. The particular geometry of the ferrule
components have been disclosed in U.S. patent application Ser. No.
13/440,970 (Published as US2012/0257860A1). In accordance with the
present invention, webs 216 are provided at the adjacent end or
back edges of the first and second ferrule components 212 and 214,
in similar manner as the web 16 in the previous embodiment shown in
FIG. 1A. Instead of raised flanges 26 on the second ferrule
component 14 in the embodiment of FIG. 1A, raised flanges 226 are
provided on the first ferrule component 212 in the present
embodiment. A raised platform 225 is provided in the second ferrule
component 214, to define a surface (similar to surface 25 in the
embodiment of FIG. 1A) to cover the open grooves 218 on the first
ferrule component 212. The grooves 218 may be similarly structured
as grooves 18 in the previous embodiment of FIG. 1A. The raised
platform 225 fits between the raised flanges 226, with an
interference or snap fit. Further, the flanges 226 are wide enough
to be provided with grooves 251, to receive alignment guide pins
250. Each groove 251 has a longitudinal opening, and each groove is
structured (i.e., sized and shaped) to securely retain an alignment
pin 250 in the groove by clamping the alignment pin 250 (much in a
similar manner as clamping the bare terminating end section of
optical fibers 20 in grooves 218). Other than the additional
grooves 251 and the features of raised platform 225 and flanges 226
of the first and second ferrule components 212 and 214 in this
embodiment, the surface features of the opposing sides of the first
and second ferrule components 212 and 214 may be similar to those
of the ferrule assembly 10 in the previous embodiment shown in FIG.
1A. For example, recesses are provided at the opposing sides of the
first and second ferrule components 212 and 214 to define a space
to receive the sleeve 31 of the fiber ribbon 30.
[0044] In another aspect of the present invention, the grooves
and/or external geometry of the ferrule assemblies described above
are precision formed by high throughput stamping process. In one
embodiment, at least the first ferrule component is formed by
stamping to define the geometries of its external body and groove.
In another embodiment, the entire ferrule assembly is formed by
stamping to define the geometries of the first ferrule component,
the second ferrule component and the interconnecting web in a
continuous stamping operation on a stock material (e.g., a strip of
metal/alloy blank or stock). This produces a single part, which is
efficient for subsequent parts handling. It is important to note
that by stamping the body structure of first ferrule component
along with the groove, the geometry of the overall structure of the
ferrule assembly can be precisely defined. By precision stamping
the external geometries of at least the first ferrule component and
the grooves, the spacing of the grooves and the position of the
grooves with respect to the exterior surface of the first ferrule
component are precisely defined. Accordingly, the array of optical
fibers held by the ferrule assembly can be precisely aligned to the
ends of another array of optical fibers held by another similar
formed ferrule assembly by using a sleeve, without having to use
alignment guide pins (i.e., alignment is achieved by the sleeve
acting on the external structure of the ferrule assembly).
Alternatively, it is possible that the web between the two ferrule
components is made by an over-molding process. The first and second
ferrule components can be stamped on a carrier strip, and the
carrier strip is then fed with the first and second ferrule
components into an injection molding machine. The web would be
molded over the ferrule components and allowed to cool. This
provides a more compliant web that will not yield or break when
bent.
[0045] A precision stamping process and apparatus has been
disclosed in U.S. Pat. No. 7,343,770, which was commonly assigned
to the assignee of the present invention, and which is fully
incorporated by reference herein. The process and stamping
apparatus disclosed therein may be adapted to precision stamping
the ferrule assembly of the present invention. Further application
of such stamping process is disclosed in U.S. patent application
Ser. No. 13/440,970 (Published as US2012/0257860A1).
[0046] Referring to FIGS. 4A-4C, the further benefits of precision
stamping a modified embodiment of FIGS. 1A-1E to provide
complementary grooves 18' on both the sides 23' and 25' of the
first and second ferrule components 12' and 14' is explained. In
particular, FIG. 4A is a perspective view of a foldover optical
fiber ferrule assembly 10' in an opened position in accordance with
another embodiment of the present invention. FIG. 4B is a
perspective view of the ferrule assembly 10' in the closed
position. FIG. 4C is a sectional view. In this embodiment, the
first and second ferrule components 12' and 14' of the ferrule
assembly 10' are structured generally similar to the ferrule
assembly 10 in FIG. 1A. In accordance with the present invention,
webs 16' are provided at the adjacent end or back edges of the
first and second ferrule components 12' and 14', in a similar
manner as the web 16 in the previous embodiment shown in FIG. 1A.
In this embodiment, each of the first and second ferrule components
12' and 14' are provided with open half grooves 18', which combine
to form a circular closed groove to retain the bare termination
section of the optical fibers 20 (as more clearly shown in the
sectional view in FIG. 4C). Other than the grooves 18', the surface
features of the opposing sides of the first and second ferrule
components 12' and 14' may be similar to those of the ferrule
assembly 10 in the previous embodiment shown in FIG. 1A. For
example, recesses 3'' and 34' are provided at the opposing sides
22' and 24' of the first and second ferrule components 12' and 14'
to define a space to receive the sleeve 31 of the fiber ribbon 30.
Raised flanges 26' may also be provided along the lateral edges of
the first and second ferrule components 12' and 14'.
[0047] The embodiment of FIG. 4 allows a greater degree of accuracy
in the alignment of optical fibers 20 by allowing the grooves 18'
in surface 23' and the matching grooves 18' in surface 25' to be
formed with a single stamping tool. In a stamping or forging
process, the punch (or die) can form both sets of grooves 18' on
the first and second ferrule components 12' and 14', using a single
set of features that are manufactured on the face of a punch.
Consequently, the alignment and pitch between these features is
inherently matched between the two opposing surfaces 23' and 25'
when folded about the webs 16', with corresponding grooves on the
first ferrule component 12' matching with the corresponding grooves
on the second ferrule component 14' (e.g., groove number 1 in the
first ferrule component 12' is always matched with groove number 1
in the second ferrule component 14', groove number 2 matched with
groove number 2, and so on.) Furthermore, the webs 16' joining the
two ferrule components 12' and 14' assure that when the ferrule
assembly is used (e.g., deployed in the field), the first and
second ferrule components 12' and 14' are always mated pairs so
that in high-volume production, ferrule components produced from
different tools and different production conditions/parameters are
never mixed. This reduces the manufacturing variations between the
two ferrule components used in a ferrule assembly, as ferrule
components from the same production batch are matched always with
the web tethering two ferrule components to be used to form a
ferrule assembly. This degree of matching in the groove features
could not be guaranteed in volume production if the ferule
components 12' and 14' were manufactured without the webs 16. The
groove of one ferrule component produced from one production batch
may not match up as well to the groove of another ferrule component
produced from another production batch.
[0048] In one embodiment, the above-described ferrule assemblies
are made of a metal/alloy material (which may be a malleable stock
material suitable for stamping to form the above described features
of the ferrule assemblies), which may be chosen to have high
stiffness (e.g., stainless steel), chemical inertness (e.g.,
titanium), high temperature stability (nickel alloy), low thermal
expansion (e.g., Invar), or to match thermal expansion to other
materials (e.g., Kovar for matching glass). For certain
applications, the ferrule assemblies may be made of polymers.
[0049] The ferrule assembly in accordance with the present
invention further improves the current ferrule designs, which can
be incorporated in an optical fiber connector to result in low
insertion loss and low return loss, and which provides ease of use
and high reliability with low environmental sensitivity, and which
can be fabricated at low cost. The one-piece ferrule assembly
design facilitates ease of use to affix the end sections of an
array of optical fibers of a fiber ribbon to a ferrule (in this
case a ferrule formed by a ferrule assembly in accordance with the
present invention). The ferrule thus formed by the one-piece
ferrule assembly can be adapted for use in an optical fiber
connector.
[0050] FIG. 5 illustrates an example of an optical fiber connector
1400 for a cable 1410 containing optical fibers 1412, which may be
similar to connectors commercialized by other providers, which
incorporates the inventive ferrule assembly 1402 (which may take
the form disclosed above in connection with FIGS. 1-3) instead of a
prior art ferrule. The connector includes an assembly of components
consisting of the ferrule assembly 1402 (as will be further
elaborated below), a ferrule housing 1404, a cable boot 1406,
alignment guide pins 1408, and other hardware provided within
and/or outside the housing (e.g., cable strain relief, crimp,
biasing spring, spacer, etc.). The ferrule assembly in accordance
with the present invention may be made backward compatible to be
used to replace the existing ferrules in the optical fiber
connectors offered by other providers.
[0051] While the invention has been particularly shown and
described with reference to the preferred embodiments, it will be
understood by those skilled in the art that various changes in form
and detail may be made without departing from the spirit, scope,
and teaching of the invention. Accordingly, the disclosed invention
is to be considered merely as illustrative and limited in scope
only as specified in the appended claims.
* * * * *