U.S. patent application number 17/315610 was filed with the patent office on 2021-08-26 for optical connector.
The applicant listed for this patent is 3M INNOVATIVE PROPERTIES COMPANY. Invention is credited to Barry S. Carpenter, Takayuki Hayauchi, Terry L. Smith.
Application Number | 20210263229 17/315610 |
Document ID | / |
Family ID | 1000005571961 |
Filed Date | 2021-08-26 |
United States Patent
Application |
20210263229 |
Kind Code |
A1 |
Smith; Terry L. ; et
al. |
August 26, 2021 |
OPTICAL CONNECTOR
Abstract
An optical connector includes a first attachment area for
receiving and permanently attaching to an optical waveguide. A
light coupling unit is disposed and configured to move
translationally and not rotationally within the housing of the
connector. The light coupling unit includes a second attachment
area for receiving and permanently attaching to an optical
waveguide received and permanently attached at the first attachment
area. The light coupling unit also includes light redirecting
surface. The light redirecting surface is configured such that when
an optical waveguide is received and permanently attached at the
first and second attachment areas, the light redirecting surface
receives and redirects light from the optical waveguide. The
optical waveguide limits, but does not prevent, a movement of the
light coupling unit within the housing.
Inventors: |
Smith; Terry L.; (Roseville,
MN) ; Carpenter; Barry S.; (Oakdale, MN) ;
Hayauchi; Takayuki; (Sagamihara-shi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
3M INNOVATIVE PROPERTIES COMPANY |
St. Paul |
MN |
US |
|
|
Family ID: |
1000005571961 |
Appl. No.: |
17/315610 |
Filed: |
May 10, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16734634 |
Jan 6, 2020 |
11029468 |
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17315610 |
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16189142 |
Nov 13, 2018 |
10557995 |
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16734634 |
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15121183 |
Aug 24, 2016 |
10162123 |
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PCT/US2015/019389 |
Mar 9, 2015 |
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16189142 |
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61955304 |
Mar 19, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G02B 6/3839 20130101;
G02B 6/3882 20130101; G02B 6/3831 20130101; G02B 6/262 20130101;
G02B 6/3829 20130101; G02B 6/3821 20130101; G02B 6/3885 20130101;
G02B 6/383 20130101 |
International
Class: |
G02B 6/38 20060101
G02B006/38; G02B 6/26 20060101 G02B006/26 |
Claims
1. A connector comprising a housing comprising: a first attachment
area for receiving and permanently attaching to an optical
waveguide; a second attachment area for receiving and permanently
attaching to an optical waveguide received and permanently attached
at the first attachment area; and a flexible carrier disposed
within the housing between the first and second attachment areas
for supporting and adhering to an optical waveguide received and
permanently attached at the first and second attachment areas, a
first end of the flexible carrier attached to the first attachment
area, a second end of the carrier attached to the second attachment
area.
2. The connector of claim 1, wherein the flexible carrier is less
flexible when initially bent and more flexible when bent
further.
3. The connector of claim 1, wherein the flexible carrier
comprises: a flexible first portion for supporting and adhering to
an optical waveguide received and permanently attached at the first
and second attachment areas; and a flexible second portion attached
to the flexible first portion at one or more discrete spaced apart
attachment locations.
4. The connector of claim 3, wherein the one or more discrete
spaced apart attachment locations, and the flexible first and
second portions define at least one gap therebetween.
5. The connector of claim 3, wherein when bent along a length of
the flexible carrier, the flexible first portion is more flexible
than the flexible second portion.
6. The connector of claim 3, wherein when unbent, the flexible
first portion has a substantially planar lateral cross-sectional
profile and the flexible second portion has a substantially
non-planar lateral cross-sectional profile.
7. The connector of claim 3, wherein as the flexible carrier is
bent along a length of the flexible carrier, a lateral
cross-sectional profile of the flexible second portion changes from
a substantially non-planar profile to a substantially planar
profile.
8. The connector of claim 7, wherein the flexible second portion is
less flexible when having a substantially non-planar lateral
cross-sectional profile and more flexible when having a
substantially planar lateral cross-sectional profile.
9. The connector of claim 3, wherein at least one attachment
location in the one or more discrete spaced apart attachment
locations extends along substantially an entire length of the
flexible carrier.
10. The connector of claim 1, wherein the flexible carrier
comprises: a flexible first portion for supporting and adhering to
an optical waveguide received and permanently attached at the first
and second attachment areas; and a flexible second portion attached
to the top portion, such that as the flexible carrier is bent along
a length of the flexible carrier, the flexible second portion
collapses onto the flexible first portion.
11. The connector of claim 10, wherein the flexible first portion
has a first lateral cross-sectional profile and the flexible second
portion has a different second lateral cross-sectional profile,
wherein as the flexible second portion collapses onto the flexible
first portion, the lateral cross-sectional profile of the flexible
second portion changes from the second lateral cross-sectional
profile to the first lateral cross-sectional profile.
12. The connector of claim 10, wherein the flexible second portion
is attached to the flexible first portion at an attachment
location, and wherein as the flexible second portion collapses onto
the flexible first portion, portions of the flexible second portion
rotate about the attachment location.
13. The connector of claim 12, wherein each of the flexible first
and second portions has a substantially planar cross-sectional
profile when bent.
14. The connector of claim 10, wherein the flexible second portion
comprises a first flexible bottom portion attached to the flexible
first portion at a first attachment location, and a second flexible
second portion attached to the flexible first portion at a
different second attachment location, wherein as the flexible
second portion collapses onto the flexible first portion, the first
flexible second portion rotates about the first attachment
location, and the second flexible second portion rotates about the
second attachment location.
15. The connector of claim 14, wherein each of the flexible first
portion, first flexible second portion, and second flexible second
portion has a substantially planar cross-sectional profile when
bent.
16. The connector of claim 1, wherein the flexible carrier
comprises: a flexible first portion for supporting and adhering to
an optical waveguide received and permanently attached at the first
and second attachment areas; and a flexible second portion, such
that as the flexible carrier is bent along a length of the flexible
carrier, the flexible first and second portions slide with respect
to each other along the length of the flexible carrier.
17. The connector of claim 1, wherein when the connector is unmated
and the optical waveguide is received and permanently attached at
the first and second attachment areas, the optical waveguide is
substantially unbent between the first and second attachment
areas.
18. The connector of claim 1, further comprising a light coupling
unit disposed and configured to move within the housing, the light
coupling unit comprising: the second attachment area for receiving
and permanently attaching to the optical waveguide received and
permanently attached at the first attachment area; and a light
redirecting surface configured such that when the optical waveguide
is received and permanently attached at the first and second
attachment areas, the light redirecting surface receives and
redirects light from the optical waveguide, and the flexible
carrier and optical waveguide limit, but do not prevent, movement
of the light coupling unit within the housing.
19. The connector of claim 18, wherein as the connector mates with
a mating connector, the flexible carrier is configured to flex, to
cause the optical waveguide to bend, and to cause the light
coupling unit to rotate within the connector housing.
20. The connector of claim 18, wherein a mating of the light
coupling unit with a mating light coupling unit of a mating
connector causes the flexible carrier to flex and the optical
waveguide to bend between the first and second attachment areas,
after the mating, the flexible carrier and the optical waveguide
applying spring force to the light coupling unit and preventing the
light coupling unit from unmating from the mating light coupling
unit.
21. The connector of claim 18, wherein after the connector mates
with a mating connector, mating surfaces of the light coupling unit
and a mating light coupling unit are disposed at an angle to a
mating direction of the connector.
22. The connector of claim 18, wherein the first attachment area is
configured to move within the housing.
23. The connector of claim 22, when the optical waveguide is
received and permanently attached at the first and second
attachment areas, a mating of the light coupling unit with a mating
light coupling unit of a mating connector is configured to cause:
the first attachment area to move within the housing; the flexible
carrier to flex; a bend in the optical waveguide; and the light
coupling unit to move within the housing, wherein a spring force is
applied by the flexible carrier and the bend in the optical
waveguide to the light coupling unit, the spring force assisting in
preventing the light coupling unit from unmating from the mating
light coupling unit.
24. The connector of claim 23, wherein during the mating, the first
attachment area moves in a direction substantially perpendicular to
a connector mating direction of the connector.
25. The connector of claim 23, wherein during the mating, the first
attachment area is configured to move in a first direction and the
light coupling unit is configured to move in a second direction
different from the first direction.
26. The connector of claim 23, wherein during the mating, the light
coupling unit rotates within the housing.
27. The connector of claim 1, further comprising a registration
feature, such that as the connector mates with a mating connector
along a mating direction, the registration feature of the connector
mates with a mating registration feature of the mating connector,
the mating registration feature causing the first attachment area
of the connector to move within the housing of the connector.
28. The connector of claim 27, wherein the registration feature of
the connector comprises an elongated channel and the mating
registration feature of the mating connector comprises an elongated
protrusion, such that as the connector mates with the mating
connector, the elongated protrusion slides within the elongated
channel, a front end of the elongated protrusion sliding past the
channel and making contact with the first attachment area, the
contact causing the first attachment area to move within the
housing of the connector.
29. The connector of claim 28, wherein during the mating, the
mating registration feature engages with a contact surface of the
first attachment area and applies a force to the contact surface
causing the first attachment area of the connector to move within
the housing of the connector.
30. The connector of claim 29, wherein the contact surface is a
ramp.
31. The connector of claim 30, wherein the first attachment feature
includes a stop feature configured to limit movement of the mating
registration feature of the mating connector.
32. The connector of claim 1, further comprising at least one
compressible element, wherein movement of the first attachment area
causes the compressible element to apply spring force in a
direction opposing a direction of movement of the first attachment
area.
33. The connector of claim 32, wherein the compressible element
comprises a spring that is compressed by movement of the first
attachment area.
34. The connector of claim 1, wherein at least one of the first and
second flexible portions comprises a vibration dissipating
material.
35. The connector of claim 1 wherein at least one of the first and
second flexible portions comprises a viscoelastic material.
Description
TECHNICAL FIELD
[0001] The provided disclosure relates to optical connectors for
connecting sets of optical waveguides such as optical fiber
ribbons.
BACKGROUND
[0002] Optical fiber connectors can be used to connect optical
fibers in a variety of applications including: telecommunications
networks, local area networks, data center links, and for internal
links in high performance computers. These connectors can be
grouped into single fiber and multiple fiber designs and also
grouped by the type of contact. Common contact methods include:
physical contact wherein the mating fiber tips are polished to a
smooth finish and pressed together; index matched, wherein a
compliant material with an index of refraction that is matched to
the core of the fiber fills a small gap between the mated fibers'
tips; and air gap connectors, wherein the light passes through a
small air gap between the two fiber tips. With each of these
contact methods a small bit of dust on the tips of the mated fibers
can greatly increase the light loss.
[0003] Another type of optical connector is referred to as an
expanded beam connector. This type of connector allows the light
beam in the source connector to exit the fiber core and diverge
within the connector for a short distance before the light is
collimated to form a beam with a diameter substantially greater
than the core. In the receiving connector the beam is then focused
back to its original diameter on the tip of the receiving fiber.
This type of connector is less sensitive to dust and other forms of
contamination that may be present in the region where the beam is
expanded to the larger diameter.
[0004] Backplane optical connectors will become essential
components of high-performance computers, data centers, and telecom
switching systems in the near future, as line rates of data
transmission migrate from the current 10 Gb/sec/line to 25
Gb/sec/line in the next few years. It would be advantageous to
provide expanded beam connectors that are lower cost and higher
performance alternatives to existing optical and copper connections
that are currently being used in the 10 Gb/sec interconnects.
SUMMARY
[0005] The disclosure relates to optical connectors. Some
embodiments involve a connector that includes a first attachment
area for receiving and permanently attaching to an optical
waveguide. A light coupling unit is disposed and configured to move
translationally and not rotationally within the housing of the
connector. The light coupling unit includes a second attachment
area for receiving and permanently attaching to an optical
waveguide received and permanently attached at the first attachment
area. The light redirecting surface of the light coupling unit is
configured such that when an optical waveguide is received and
permanently attached at the first and second attachment areas, the
light redirecting surface receives and redirects light from the
optical waveguide. The optical waveguide limits, but does not
prevent, a movement of the light coupling unit within the
housing.
[0006] Some embodiments relate to a connector the includes a first
attachment area for receiving and permanently attaching to an
optical waveguide and configured to move within the housing and a
light coupling unit disposed and configured to move within the
housing. The light coupling unit comprises a second attachment area
for receiving and permanently attaching to an optical waveguide
received and permanently attached at the first attachment area. The
light coupling unit also includes a light redirecting surface which
is configured such that when an optical waveguide is received and
permanently attached at the first and second attachment areas, the
light redirecting surface receives and redirects light from the
optical waveguide. The optical waveguide limits, but does not
prevent, a movement of the light coupling unit within the
housing.
[0007] In some embodiments, a connector comprises a first
attachment area for receiving and permanently attaching to an
optical waveguide and a second attachment area for receiving and
permanently attaching to an optical waveguide received and
permanently attached at the first attachment area. A flexible
carrier is disposed within the housing of the connector between the
first and second attachment areas for supporting and adhering to an
optical waveguide received and permanently attached at the first
and second attachment areas. A first end of the flexible carrier is
attached to the first attachment area and a second end of the
carrier is attached to the second attachment area.
[0008] The above summary is not intended to describe each disclosed
embodiment or every implementation of the present disclosure. The
figures and the detailed description below more particularly
exemplify illustrative embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1A shows a side view of an optical connector prior to
mating according to some embodiments;
[0010] FIG. 1B shows the mating face of the optical connector of
FIG. 1A;
[0011] FIG. 1C shows the connector of FIG. 1A after mating;
[0012] FIG. 2A illustrates a light coupling unit in accordance with
embodiments described herein, with a fiber cable attached;
[0013] FIG. 2B shows portions of the light coupling unit of FIG. 2A
in more detail;
[0014] FIGS. 3A-3C illustrate the operation of alignment features
of a light coupling unit;
[0015] FIG. 4 depicts alignment features having a tapered profile
in accordance with some embodiments;
[0016] FIGS. 5A and 5B show an unmated and mated optical connector,
respectively, that includes a moveable first attachment area in
accordance with embodiments disclosed herein;
[0017] FIGS. 6A and 6B show an unmated and mated optical connector,
respectively, that includes a flexible carrier according to some
embodiments;
[0018] FIGS. 7A and 7B show side views of an unbent and bent
flexible carrier, respectively, according to some embodiments;
[0019] FIGS. 7C and 7D show cross sectional views of the unbent and
bent flexible carrier, respectively, of FIGS. 7A and 7B;
[0020] FIGS. 8-11 show cross sectional views of various flexible
carrier configurations.
[0021] FIGS. 12A and 12B show side views of an unbent and bent
flexible carrier, respectively, in accordance with some
embodiments;
[0022] FIGS. 12C and 12D show cross sectional views of the unbent
and bent flexible carrier, respectively, illustrated in FIGS. 12A
and 12B;
[0023] FIG. 13 is a perspective view illustrating a configuration
of an optical ferrule according to an embodiment of the
disclosure;
[0024] FIG. 14 is a perspective view illustrating a configuration
of an optical ferrule according to an embodiment of the
disclosure;
[0025] FIG. 15 is a perspective view illustrating an example of
applying of an optical ferrule according to an embodiment of the
disclosure;
[0026] FIG. 16 is a view in the direction of arrow IV in FIG.
13;
[0027] FIG. 17 is a cross-section view cut along line V-V in FIG.
16;
[0028] FIG. 18 is a view in the direction of arrow VI in FIG.
13;
[0029] FIG. 19A is a diagram for describing the method of mating
the optical ferrule according to an embodiment of the
disclosure;
[0030] FIG. 19B is a diagram for describing the method of mating
the optical ferrule according to an embodiment of the
disclosure;
[0031] FIG. 20 is a perspective view illustrating a mated condition
of the optical ferrule of an embodiment of the disclosure;
[0032] FIG. 21 is a perspective view illustrating a mated condition
of the optical connector of an embodiment of the disclosure;
[0033] FIG. 22A is a perspective view of one of the optical
connectors of FIG. 21;
[0034] FIG. 22B is a perspective view of one of the optical
connectors of FIG. 21;
[0035] FIG. 23A is a perspective view of an optical fiber unit that
is assembled into the optical connector of FIG. 22A;
[0036] FIG. 23B is a perspective view of an optical fiber unit
assembled to the optical connector of FIG. 22A;
[0037] FIG. 24 is a cross-section view along line VIII-VIII in FIG.
22B;
[0038] FIG. 25A is a perspective view of an optical fiber assembly
held in a case of the connector of FIG. 22A;
[0039] FIG. 25B is a perspective view of an optical fiber assembly
held in a case of the connector of FIG. 22A.
[0040] FIG. 26 is a view in the direction of arrow XV in FIG.
25A;
[0041] FIG. 27A is a perspective view where the right side body has
been omitted from the optical fiber assembly of FIG. 25A;
[0042] FIG. 27B is a perspective view where the right side body has
been omitted from the optical fiber assembly of FIG. 25B;
[0043] FIG. 28 is a view in the direction of arrow XVII in FIG.
27A;
[0044] FIG. 29A is a perspective view of another optical connector
of FIG. 21;
[0045] FIG. 29B is a perspective view of another optical connector
of FIG. 21;
[0046] FIG. 30A is a perspective view of an optical fiber unit
assembled into the optical connector of FIG. 29A;
[0047] FIG. 30B is a perspective view of the optical fiber unit
incorporated into the optical connector of FIG. 29A;
[0048] FIG. 31 is a view in the direction of arrow XX of FIG.
30B;
[0049] FIG. 32A is a perspective view where the left side body has
been omitted from the optical fiber assembly of FIG. 30A;
[0050] FIG. 32B is a perspective view where the left side body has
been omitted from the optical fiber assembly of FIG. 30B;
[0051] FIG. 33 is a cross-section view cut along line XXII-XXII of
FIG. 29A.
[0052] FIG. 34 is a cross-section view showing the mated condition
of the connector according to an embodiment of the disclosure;
[0053] FIG. 35 is a diagram schematically illustrating the function
of the connector according to an embodiment of the disclosure;
[0054] FIG. 36 is a diagram schematically illustrating the function
of the connector according to an embodiment of the disclosure;
[0055] FIG. 37 is a diagram illustrating a modified example of FIG.
35;
[0056] FIG. 38 is a diagram illustrating a modified example of FIG.
36;
[0057] FIG. 39 is a diagram illustrating another modified example
of FIG. 36; and
[0058] FIG. 40 is a diagram illustrating another modified example
of FIG. 35.
[0059] The figures are not necessarily to scale. Like numbers used
in the figures refer to like components. However, it will be
understood that the use of a number to refer to a component in a
given figure is not intended to limit the component in another
figure labeled with the same number.
DETAILED DESCRIPTION
[0060] In the following description, reference is made to the
accompanying drawings that form a part hereof and in which are
shown by way of illustration. It is to be understood that other
embodiments are contemplated and may be made without departing from
the scope or spirit of the present disclosure. The following
detailed description, therefore, is not to be taken in a limiting
sense.
[0061] FIG. 1A shows a side view and FIG. 1B a view of the mating
face 104 of a connector 100 according to some embodiments. FIG. 1A
shows a mating connector 101 prior to mating with connector 100.
FIG. 1C shows connectors 100, 101 after mating.
[0062] The configuration and operation of the connectors 100, 101
is explained primarily with reference to connector 100 with the
understanding that mating connector 101 includes similar features.
As shown in FIG. 1A-1C, in some embodiments, the connector 100 may
include one or more first attachment areas 110 configured for
permanently attaching one or more optical waveguides 115. A light
coupling unit 120 is disposed within the housing 105 and is
optically coupled to a waveguide 115. The optical waveguide 115 may
be one optical waveguide of a plurality of waveguide arranged side
by side in a multiple fiber ribbon cable, as shown in more detail
in FIGS. 2A-2C. The multiple fibers in a fiber cable can bend in
unison and by the substantially the same amount when the connector
engages, rather than individually. The light coupling unit 120 is
configured to move translationally, e.g., along the mating/unmating
direction of the connector (as indicated by double headed arrow
199) but not rotationally within the housing 105.
[0063] The light coupling unit 120 includes a second attachment
area 121 for receiving and permanently attaching to the optical
waveguide 115. The light coupling unit 120 includes a light
redirecting surface 122 configured such that when the optical
waveguide 115 is received and permanently attached at the first 110
and second 121 attachment areas, the light redirecting surface 122
receives and redirects light from the optical waveguide 115. The
optical waveguide 115 limits, but does not prevent, movement of the
light coupling unit 120 within the housing 105. In the embodiment
illustrated in FIG. 1A the first attachment area 110 is fixed
within the housing. In other embodiment, see, e.g., FIGS. 5A, 5B,
6A, 6B, the first attachment area is configured to move within the
housing.
[0064] As best seen in FIG. 1C, when the optical waveguide 115 is
received and permanently attached at the first 110 and second 121
attachment areas, mating of the light coupling unit 120 with a
mating light coupling unit 130 of the mating connector 101 causes a
bend 135 in the optical waveguide 115 between the first 110 and
second 121 attachment areas. The bend 135 assists in preventing the
light coupling unit 120 from unmating from the mating light
coupling unit 130. In some configurations, the bend exists when the
connector is unmated and mating causes a further bend in the
existing bend. For example, further bending of the optical
waveguide 115 may occur when, during mating, the second attachment
area 121 moves within the connector housing 105 along the
mating/unmating axis 199. After mating, the optical fiber 115
applies a spring force to the light coupling unit 120 to maintain
the light coupling unit 120 in a mating position with respect to
the mating light coupling unit 130.
[0065] In some embodiments, the housing 105 includes at least one
guide 141 configured to prevent the light coupling unit 120 from
rotating, but not moving translationally, within the housing 105.
As shown in FIG. 1A, the guide 140 may be disposed adjacent to and
facing at least one of a top 120a and a bottom 120b major surface
of the light coupling unit 120. In some implementations, the
housing 105 comprises a pair of guides 141, 142. One guide of the
pair of guides 141, 142 is disposed on each side of the light
coupling unit 120. The pair of guides 141, 142 are configured to
prevent the light coupling unit 120 from rotating, but not moving
translationally, within the housing 105. In some configurations,
one guide 141 of the pair of guides is disposed adjacent to and
facing a top major surface 120a of the light coupling unit 120 and
another guide 142 of the pair of guides is disposed adjacent to and
facing a bottom major surface 120b of the light coupling unit
120.
[0066] Some embodiments include a first registration feature 151
configured to engage with a compatible second mating registration
feature 162 of a mating connector 101. For example, the first
registration feature 151 may comprise an elongated protrusion and
the compatible second mating feature 162 may comprise an elongated
channel. As illustrated in FIG. 1A, the connector 100 can include a
first registration feature 151 which is an elongated protrusion and
a second registration feature 152 which is an elongated channel.
The first and second registration features 151, 152 of connector
100 are configured to mate with mating second and first mating
registration features 162, 161 of mating connector 101.
[0067] FIG. 2A is a more detailed view illustrating an example of a
light coupling unit 220, with an array of waveguides (e.g. fiber
cable) attached.
The second attachment area 221 may comprise plurality of V-grooves
214 each groove being configured to accommodate a different optical
waveguide 215 of a plurality of optical waveguides of a waveguide
ribbon. Each of the optical waveguides 215 being received and
permanently attached to at the first attachment area (not shown in
FIG. 2A), the optical waveguide 215 being bonded to the second
attachment area 221 at the groove 214. As shown in the embodiment
of FIG. 2A, the second attachment area 221 can permanently attach
to a plurality of optical waveguides received and permanently
attached to at the first attachment area. In some embodiments, the
optical waveguide 215 is attached at the first attachment area (not
shown in FIG. 2, but shown in FIG. 1), the second attachment area
221, or both, using an adhesive. In cases where the optical
waveguides are optical fibers, the fiber attachment areas may
consist of cylindrical holes into which the fibers are bonded. Also
in cases where the waveguides are optical fibers, the polymer
buffer layer on the fiber may be bonded to an attachment area
adjacent to the area where the bare fiber is bonded, in order to
enhance the mechanical strength of the assembly.
[0068] Light coupling unit 220 is configured so as to be able to
move translationally but not rotationally within housing 105 shown
in FIG. 1A. This facilitates proper alignment of light coupling
unit 220 with a mating coupler (typically a coupler with
substantially identical features) as will be shown in subsequent
drawings.
[0069] In some embodiments, the light coupling unit is a parallel
expanded beam optical coupler. The light directing surface 216 may
be curved so that it focuses incident light. The optical waveguide
215 has a first core diameter and the curvature of the light
directing surface 216 is configured to change a divergence of light
from the optical waveguide 215 such that light from the optical
waveguide exits the connector along an exit direction different
than a mating direction of the connector and has a second diameter
greater than the first core diameter. In some embodiments, the
ratio of the second diameter to the first core diameter can be at
least 2, at least 3.7, or even at least 5. In various embodiments,
the light directing surface 216 and optical waveguide 215 may be
operated in unidirectional mode or may be operated in a time
multiplexed bidirectional mode.
[0070] Light coupling unit 220 can also include mechanical mating
tab 236 (guide part) and interlocking mechanism 238. In some
embodiments, mechanical mating tab 236 can have a tapering width
along at least a portion of a length of the tab portion as shown in
the illustrations. Mechanical mating tab 236 can extend within
housing 105 (shown in FIG. 1A) such that when mating with a mating
connector, the connector moves toward the mating connector in a
mating direction along the mating axis 199.
[0071] FIG. 2B shows a portion of the light coupling unit 220
including the second attachment area 221 and light directing
surface 216. FIG. 2B illustrates the attachment of several optical
fibers 215 to light coupling unit 220. FIG. 2B, is a cut-away
perspective view of the light coupling unit 220 including second
attachment area 221, and light directing surface 216. At the second
attachment area 221, optical fibers 215 are aligned in grooves 214,
typically V-grooves, to which they are permanently attached. As
shown, light coupling unit 120 includes an array of light directing
surfaces 216, at least one for each optical fiber 215 attached to
light coupling unit 220. In various configurations, the light
directing surface 216 includes a prism or a curved surface.
[0072] FIGS. 3A and 3B show a light coupling unit 320 and a mating
light coupling unit 340 before and after mating, respectively. FIG.
3C shows a cross sectional view of light coupling unit 320 through
plane A-A'. Each light coupling unit 320, 340 includes a second
attachment area 321, 341, e.g., comprising V-grooves 322 for
aligning optical waveguides, and a light directing surface 335,
355. Each light coupling unit 320, 340 includes a first alignment
feature 370, 390, e.g., comprising a mechanical tab (guide part),
and a compatible second alignment feature 360, 380, e.g. comprising
a guide hole configured to receive the tab 370, 390. During mating
of the light coupling unit 320 with the mating light coupling unit
340, the first alignment feature 370 of the lighting coupling unit
320 is configured to engage with the second alignment feature 380
of the mating light coupling unit 340. The second alignment feature
360 of the light coupling unit 320 is configured to engage with a
mating first alignment feature 390 of the mating light coupling
unit 340. After mating, the light directing surface 335 of light
coupling unit 320 is aligned in mating position with the light
directing surface 355 of mating light coupling unit 340.
[0073] FIG. 4 illustrates light coupling units 420, 440 that
include additional alignment features. In the illustrated
implementation, the guide hole 460, 480 of each light coupling unit
420, 440 comprises a first end 460a, 480a and a second end 460b,
480b.
[0074] During mating of the light coupling unit 420 with the mating
light coupling unit 440, the first end 460a of the guide hole 460
engages with a tab 490 of the mating light coupling unit 440 before
the second end 460b of the guide hole 460 engages with the mating
tab 490 of the mating light coupling unit 440. The first end 460a
of the guide hole 460 includes a taper 460c that causes the guide
hole 460 to become narrower with distance from the first end 460a
towards the second end 460b for at least a portion of the length of
the guide hole 460. Similarly, during mating of the light coupling
unit 420 with the mating light coupling unit 440, the first end
480a of the guide hole 480 engages with a tab 470 of the light
coupling unit 420 before the second end 480b of the guide hole 480
engages with the mating tab 470. The first end 480a of the guide
hole 480 includes a taper 480c that causes the guide hole 480 to
become narrower with distance from the first end 480a towards the
second end 480b for at least a portion of the length of the guide
hole 480.
[0075] FIGS. 5A and 5B illustrate connectors 500, 501, each having
a first attachment area 510 that is moveable within the connector
housing 505, 506. FIGS. 5A and 5B illustrate connectors 500, 501
during and after mating, respectively. The configuration and
operation of the connectors 500, 501 is explained primarily with
reference to connector 500 with the understanding that mating
connector 501 includes similar features. Connector 500 includes a
first attachment area 510 configured for receiving and permanently
attaching to an optical waveguide 515. The first attachment area
510 is configured to move within the housing 505. A light coupling
unit 520 is disposed and configured to move within the housing 505.
The light coupling unit 520 comprises a second attachment area 521
configured to receive and permanently attach to the optical
waveguide 515 received and permanently attached at the first
attachment area 510. The light coupling unit 520 includes a light
redirecting surface 522 configured such that when an optical
waveguide 515 is received and permanently attached at the first and
second attachment areas 510, 521, the light redirecting surface 522
receives and redirects light from the optical waveguide 515, and
the optical waveguide 515 limits, but does not prevent, movement of
the light coupling unit 520 within the housing 515. For example,
the optical waveguide 515 limits, but does not prevent, the
movement of the light coupling unit 520 within the housing
primarily along a linear direction such as along the connector
mating/unmating axis indicated by arrow 599. In the absence of any
optical waveguide received and permanently attached at the first
and second attachment areas 510, 521, the light coupling unit 520
is unrestrained to move freely along at least one direction, e.g.,
a direction along the mating/unmating axis. When attached to the
optical waveguide 515, the light coupling unit 520 is stably
supported within the housing 505. The stable support is due, at
least in part, to the optical waveguide 515 being received and
permanently attached at the first and second attachment areas 510,
521.
[0076] In some embodiments, prior to mating, when the optical
waveguide 515 is received and permanently attached at the first and
second attachment areas 510, 521, the optical waveguide 515 is
substantially unbent between the first 510 and second 521
attachment areas. The light coupling unit 520 is configured to be
so positioned and oriented within the housing 505 as to mate with a
light coupling unit 540 of a mating connector 501. As the connector
500 mates with the mating connector 501, the light coupling unit
520 is positioned and oriented for mating, at least in part, by
virtue of the optical waveguide 515 being received and permanently
attached at the first 510 and second 521 attachment areas.
[0077] As shown in FIG. 5B, when the optical waveguide 515 is
received and permanently attached at the first and second
attachment areas 510, 521, mating of the light coupling unit 520
with a mating light coupling unit 540 of a mating connector 505
causes a bend 516 in the optical waveguide 515 between the first
510 and second 521 attachment areas. The bend 516 applies spring
force to the light coupling unit 520 which assists in preventing
the light coupling unit 520 from unmating from the mating light
coupling unit 540. In some configurations, the bend may be an
S-shaped bend, for example. In some cases, when the optical
waveguide 515 is received and permanently attached at the first and
second attachment areas 510, 521, the optical waveguide 515 already
has a bend before mating, and mating of the light coupling unit to
a mating light coupling unit cases a further bend in the existing
bend.
[0078] As indicated in FIG. 5B, when the optical waveguide 515 is
received and permanently attached at the first and second
attachment areas 510, 521, mating of the light coupling unit 520
with the mating light coupling unit 540 of the mating connector 501
causes the first attachment area 510 of connector 500 to move
within the housing 505 along the direction indicated by arrow 590.
The first attachment area 510 of connector 501 moves in an opposite
direction, along arrow 591. The movement of the first attachment
area 510 causes a first bend 516a and second bend 516b in the
optical waveguide 515 and causes the light coupling unit 520 to
move within the housing 505. The first and second bends assists in
preventing the light coupling unit 520 from unmating from the
mating light coupling unit 540. In various embodiments, the first
bend 516a, the second bend 516b, or both, may comprise a further
bend in an existing bend present before the connectors 500, 501 are
mated. As indicated by arrows 590 and 599, during mating, the first
attachment area 510 moves in a direction 590 substantially
perpendicular to a connector mating direction 599 of the connector
500. The light coupling unit 520 moves substantially parallel to
the connector mating direction 599 and toward the first attachment
area 510.
[0079] In the illustrated embodiment, the connector 500 includes
first and second registration features 551, 552 configured to
engage with compatible mating registration features 561, 562 of
mating connector 501. As the connector 500 mates with a mating
connector 501 along the mating direction 599, the second
registration feature 552 of the connector 500 mates with the first
mating registration feature 561 of the mating connector 501. The
first mating registration feature 561 of the mating connector 501
causes the first attachment area 510 of the connector 500 to move
along arrow 590 within the housing 505 of the connector 500.
[0080] For example, in some implementations, the registration
feature 552 of the connector 500 defines an elongated channel and
the registration feature 561 of the mating connector 501 comprises
an elongated protrusion. As the connector 500 mates with the mating
connector 501, the elongated protrusion 561 slides within the
channel 552. During mating, the front end 561a of the elongated
protrusion 561 slides past the channel 552 and makes contact with
the first attachment area 510. The contact between the elongated
protrusion 561 and the first attachment area 510 causes the first
attachment area 510 to move within the housing 505 of the connector
500.
[0081] During mating of the connector 500 with mating connector
501, the first attachment area 510 of connector 500 is configured
to move in a first direction, along arrow 590, and the light
coupling unit 520 is configured to move in a second direction,
along mating axis 599, which is different from the first direction
590. The first attachment area 510 of connector 501 is configured
to move in an opposite direction from the first direction, along
arrow 591, and the light coupling unit 540 is configured to move in
a second direction, along mating axis 599, which is different
direction 59. In some configurations, directions 590 and 591 are
substantially orthogonal to the mating axis 599.
[0082] As shown in FIGS. 5A and 5B, the first attachment feature
510 can have a contact surface 510a configured to cause movement of
the first attachment feature 510 during mating of the connector 500
to the mating connector 501 as the registration feature 561 of the
mating 501 connector engages with the contact surface 510a. For
example, as shown in FIG. 5A, the contact surface 510a can be a
ramp. The first attachment feature 510 can also include a stop
feature 510b configured to limit movement of the registration
feature 561 of the mating connector 501.
[0083] A compressible element 550 may be disposed within the
housing 505 that applies spring force that opposes the movement of
the first attachment area 510 along direction 590. In some
embodiments, the compressible element is a spring. In some
embodiments, the compressible element 550 is compressed or is
further compressed by the movement of the first attachment area. In
some embodiments, the compressible element 550 is extended or
extended further by the movement of the first attachment area. The
housing 505 may include one or more features 511 that extend along
the first attachment area 510 along direction 590. The features 511
guide the movement of the first attachment area 510 and/or
stabilize the first attachment area 510 within the housing 505.
[0084] In some embodiments, the housing 505 includes at least one
guide 541 arranged to prevent or at least limit the light coupling
unit 540 from rotating within the housing 505. The at least one
guide 541 does not prevent the light coupling unit 540 from moving
translationally, e.g., along axis 599, within the housing 505. For
example, the at least one guide can be disposed adjacent to and
facing at least one of a top and bottom major surface 520a, 520b of
the light coupling unit 520.
[0085] According to some implementations, the housing 505 includes
a pair of guides 541, 542, one on each side of the light coupling
unit 520. One guide 541 may be disposed adjacent to and facing a
top major surface 520a of the light coupling unit 520, and the
other guide 542 in the pair of guides is disposed adjacent to and
facing a bottom major surface 520b of the light coupling unite 520.
The pair of guides 541, 542 prevent or at least limit rotation of
the light coupling unit 520 within the housing 505 but do not
substantially restrict the light coupling unit 520 from moving
translationally within the housing 505.
[0086] As shown in FIGS. 6A and 6B, some embodiments include a
flexible carrier 670 configured to adhere to and support the
optical waveguide. FIGS. 6A and 6B respectively show connector 600
during mating and after mating with mating connector 601. In
embodiments that include a flexible carrier, rotational movement of
the light coupling unit may not be restricted such as by guides
541, 542 shown in FIG. 5A. The connector 600 includes a first
attachment area 610 configured to receive and permanently attach to
an optical waveguide 615 and a second attachment area 621
configured to receive and permanently attach to the optical
waveguide 615 received and permanently attached at the first
attachment area 610. A flexible carrier 670 is disposed within the
housing 605 between the first and second attachment areas 610, 621
for supporting and adhering to the optical waveguide 615. A first
end 671a of the flexible carrier 671 may be attached to the first
attachment area 610 and a second end 671b of the flexible carrier
671 may be attached to the second attachment area 621.
[0087] According to some aspects, when the connector 600 is unmated
and the optical waveguide 615 is received and permanently attached
at the first and second attachment areas 610, 621, the flexible
carrier 670 and the optical waveguide 615 are substantially unbent
between the first and second attachment areas 610, 621. During
mating, the flexible carrier 670 bends, causing the optical
waveguide 615 to also bend.
[0088] According to some aspects, when the connector 600 is unmated
and the optical waveguide 615 is received and permanently attached
at the first and second attachment areas 610, 621, the flexible
carrier 670 and the optical waveguide 615 are bent between the
first and second attachment areas 610, 621. During mating, the
flexible carrier 670 bends further, causing the optical waveguide
615 to also bend further. The flexible carrier 670 is less flexible
when unbent or when initially bent and is more flexible when bent
or bent further.
[0089] Connector 600 also includes a light coupling unit 620
disposed and configured to move within the housing 605. The light
coupling unit 620 comprises the second attachment area 621 for
receiving and permanently attaching to the optical waveguide
received and permanently attached at the first attachment area 610.
The light coupling unit also includes a light redirecting surface
622 configured such that when the optical waveguide 615 is received
and permanently attached at the first and second attachment areas
610, 621, the light redirecting surface 622 receives and redirects
light from the optical waveguide 615. The flexible carrier 670 and
optical waveguide 615 limit, but do not prevent, movement of the
light coupling unit 620 within the housing 605.
[0090] When connector 600 mates with mating connector 601, the
flexible carrier 670 is configured to bend or to bend further,
which causes the optical waveguide 615 to bend or bend further. The
bending or further bending of the optical waveguide 615 causes the
light coupling unit 620 to rotate within the connector housing 605.
Mating of the light coupling unit 620 with a mating light coupling
unit 640 of the mating connector 601 causes the flexible carrier
670 and the optical waveguide 615 to bend or bend further between
the first 610 and second 621 attachment areas. After the mating,
the flexible carrier 670 and the optical waveguide 615 apply spring
force to the light coupling unit 620 that prevents the light
coupling unit 620 from unmating from the mating light coupling unit
640. After the connector 600 mates with a mating connector 601,
mating surfaces of the light coupling unit and a mating light
coupling unit are disposed at an angle, .theta., with respect to a
mating axis 699 of the connector 605.
[0091] In some embodiments, and as illustrated by FIGS. 6A and 6B,
the first attachment area 610 can be configured to move within the
housing 605. When the optical waveguide 615 is received and
permanently attached at the first 610 and second 621 attachment
areas, a mating of the light coupling unit 620 with the mating
light coupling unit 640 of the mating connector 601 is configured
to cause: 1) the first attachment area 610 to move within the
housing 605; 2) the flexible carrier 670 to bend or bend further;
3) the optical waveguide 615 to bend or bend further; and 4) the
light coupling unit 620 to move at least rotationally within the
housing 605. After mating, a spring force is applied to the light
coupling unit 620 by virtue of the bend in the flexible carrier 670
and the bend in the optical waveguide 615. The spring force assists
in preventing the light coupling unit 620 from unmating from the
mating light coupling unit 640.
[0092] During mating, the first attachment area 610 moves in a
direction substantially perpendicular to the mating axis 699 of the
connector 600. The first attachment area 610 is configured to move
in a first direction, e.g., as indicated by arrow 690 in FIG. 6B,
and the second attachment area 621 moves in a different direction
which may be orthogonal to the direction of movement of the first
attachment area 610.
[0093] As previously discussed in conjunction with FIGS. 5A and 5B,
the connector may comprise first and second registration features
651, 652 that are compatible with first and second mating
registration features 661, 662 of the mating connector 601. The
first mating registration feature 661 of the mating connector 601
can engage with a contact surface 610a of the first attachment area
610. Engagement between the first mating registration feature 661
and the contact surface 610a applies a force to the first
attachment area 610, causing the first attachment area 610 to move
within the housing 605 along the direction 590. In some
configurations, the first registration features 651, 661 of the
connectors 600, 601 are or include elongated protrusions and the
second registration features 652, 662 are or include elongated
channels. As the connector 600 mates with the mating connector 601,
the elongated protrusion 661 of the mating connector 601 slides
within the elongated channel 652 of the connector 600. A front end
661a of the elongated protrusion 661 slides past the channel 652
and makes contact with the contact area 610a of the first
attachment area 610. For example, the contact surface 610a may be
or include a ramp. The first attachment feature 610 includes a stop
feature 610b configured to limit movement of the mating
registration feature 661 of the mating connector 601.
[0094] According to some aspects, the connector 600 may include at
least one compressible element 650 arranged so that movement of the
first attachment area 610 causes the compressible element 650 to
apply spring force in a direction opposing a direction of movement
690 of the first attachment area 610. For example, the compressible
element 650 can include a spring that is compressed or extended by
movement of the first attachment area 610. The housing can include
a guide 611 that extends along the first attachment region 610
configured to guide the movement of the first attachment region
along direction 690.
[0095] FIGS. 7A-7D illustrate additional details of a flexible
carrier configured for controlling the bend force as a function of
the degree of bending in accordance with some embodiments. FIG. 7A
shows a side view and FIG. 7C shows an end lateral cross sectional
view of an unbent flexible carrier 700. FIGS. 7B and 7D show side
and lateral cross sectional views, respectively, of the flexible
carrier 700 after it is bent.
[0096] The flexible carrier 700 includes a flexible first portion
710 for supporting and adhering to an optical waveguide (not shown
in FIGS. 7A-7D) and a flexible second portion 720 attached to the
flexible first portion 710 at one or more discrete spaced apart
attachment locations 730. One or more gaps 731 may be defined
between the one or more discrete spaced apart attachment locations
730 and the flexible first 710 and second 720 portions. In some
configurations, the least one attachment location 730 extends along
substantially an entire length of the flexible carrier 700.
[0097] When bent along a length of the flexible carrier 700, as
shown in FIGS. 7C and 7D, the flexible first portion 710 is more
flexible than the flexible second portion 720. The first and/or
second portions may be or comprise one or more of spring steel,
other metal alloy springs, thermoplastic polymers, thermoset
polymers, and polymer-inorganic composites, for example.
[0098] As the flexible carrier 700 is bent along a length of the
flexible carrier 700, the flexible second portion 720 may collapse
onto the flexible first portion 710. As shown in FIG. 7C, the
flexible first portion 710 has a first lateral cross-sectional
profile and the flexible second portion 720 has a different second
lateral cross-sectional profile. As the flexible second portion 720
collapses onto the flexible first portion 710, the lateral
cross-sectional profile of the flexible second portion 720 changes
from the second lateral cross-sectional profile to the first
lateral cross-sectional profile. For example, the second lateral
cross-sectional profile may be semicircular as shown in FIG. 7C,
FIG. 9 and FIG. 10 or angled as shown in FIG. 8, FIG. 11, and FIG.
12.
[0099] For example, as best seen in FIG. 7C, when unbent, the
flexible first portion 710 has a substantially planar lateral
cross-sectional profile and the flexible second portion 720 has a
substantially non-planar lateral cross-sectional profile. As the
flexible carrier 700 is bent along a length of the flexible carrier
700, a lateral cross-sectional profile of the flexible second
portion 720 changes from a substantially non-planar profile (as
shown in FIG. 7C) to a substantially planar profile (as shown in
FIG. 7D. The flexible second portion 720 can be less flexible when
having a substantially non-planar lateral cross-sectional profile
and more flexible when having a substantially planar lateral
cross-sectional profile.
[0100] For some configurations, the flexible second portion 720 is
attached to the flexible first portion 710 at an attachment
location 730. As the flexible second portion 720 collapses onto the
flexible first portion 710, the flexible second portion 720 rotates
about the attachment location 730. The direction of rotation is
indicated by arrows 798 and 799 in FIG. 7C.
[0101] FIGS. 8 through 11 show cross sectional profiles of flexible
carriers 800, 900, 1000, 1100 in accordance with various
implementations. Each of the flexible carriers 800, 900, 1000, 1100
include a flexible second portion 820, 920, 1020, 1120 attached to
a flexible first portion 810, 910, 1010, 1110 for supporting and
adhering to an optical waveguide. For each of the flexible carriers
800, 900, 1100, when unbent, a majority of flexible first portion
810, 910, 1010 1110 has a substantially planar lateral
cross-sectional profile and a majority of flexible second portion
810, 910, 1010, 1110 has a substantially non-planar lateral
cross-sectional profile. As the flexible carrier 800, 900, 1000,
1100 is bent along a length of the flexible carrier 800, 900, 1000,
1100, a lateral cross-sectional profile of the flexible second
portion 812, 920, 1020, 1120 changes from a substantially
non-planar profile (as shown in FIG. 7C) to a substantially planar
profile (as shown in FIG. 7D. The flexible second portion 820, 920,
1020, 1120 can be less flexible when having a substantially
non-planar lateral cross-sectional profile and more flexible when
having a substantially planar lateral cross-sectional profile.
After bending, each of the flexible first and second portions has a
substantially planar cross-sectional profile.
[0102] In some embodiments, as illustrated by FIG. 12, a flexible
carrier 1200 includes a flexible first portion 1210 for supporting
and adhering to an optical waveguide and a flexible bottom portion
1220. The flexible carrier 1200 is configured so that as the
flexible carrier 1200 is bent along a length of the flexible
carrier 1210, the flexible first 1210 and second 1220 portions
slide with respect to each other along the length of the flexible
carrier 1200.
[0103] FIGS. 12A-12D illustrate additional details of a flexible
carrier in accordance with some embodiments. FIG. 12A shows a side
view and FIG. 12C shows an end lateral cross sectional view of an
unbent flexible carrier 1200. FIGS. 12B and 12D show side and
lateral cross sectional views, respectively, of the flexible
carrier 1200 after it is bent. As shown in FIGS. 12A-12D, the
flexible top portion 1210 and the flexible bottom portion 1220
include a knob 1221 (or rod) and socket 1211 coupling with
sufficient clearance between the ball and socket to allow the
flexible bottom portion 1220 to slip relative to the flexible top
portion 1210 during the bending. In some configurations, the
flexible carrier may include multiple ball/rod and socket couplings
extending along the lengths of the first and second flexible
portions 1210, 1220.
[0104] As the flexible carrier 1200 is bent along a length of the
flexible carrier 1200, the flexible second portion 1220 collapses
onto the flexible first portion 1210. As shown in FIG. 12C, when
unbent, the flexible first portion 1210 has a first lateral
cross-sectional profile and the flexible second portion 1220 has a
different second lateral cross-sectional profile. As the flexible
second portion 1220 collapses onto the flexible first portion 1210
and slips along the flexible first portion, the lateral
cross-sectional profile of the flexible second portion 1220 changes
from the unbent lateral cross-sectional profile shown in FIG. 12C
to the bent lateral cross-sectional profile as shown in FIG.
12D.
[0105] In addition to the ability of the flexible carrier to
control the bend force as a function of the degree of bending, the
flexible carrier can provide other functions. The optical fibers or
waveguides discussed herein may include a core with cladding around
the core, a buffer coating over the cladding, and a jacket around
the coatings of multiple individual fibers. The jacket binds the
individual fibers into a fiber cable, such as a fiber ribbon cable.
The core and cladding may be glass, and the coating and jacket may
be or comprise a polymeric material. The coating and jacket can
contribute significantly to the force required to bend the fiber
ribbon cable. Furthermore, if the waveguides extend between the
first and second attachment areas are fibers with polymer buffer or
jacketing, the elastic properties of the waveguide may change over
time as the buffer and/or jacket become brittle due to aging,
especially at high temperature. Additionally, if the fiber cable is
held in a pre-bent position for a long time, the coatings may
"self-anneal," gradually contributing less to the bending force of
the fiber cable. Thus, the bending force of the fiber-buffer-jacket
assembly may vary over time, causing variations in connector
performance. This effect can be reduced by the proper choice of the
materials and design for the flexible carrier. For example, one or
more of the flexible portions 710 and 720 of the flexible carrier
700 shown in FIGS. 7A-7D can be fabricated from a very stable
material such as spring steel, whose bending force dominates that
of the cable, thereby reducing variation of the total bending force
(fiber cable+flexible carrier).
[0106] In one implementation, the first flexible portion 710 of the
flexible carrier 700 shown in FIG. 7C may be made from a flat piece
of spring steel, and the second flexible portion 720 from a curved
piece of spring steel (much like a typical steel measuring tape).
For a 12-fiber optical ribbon cable 1 cm long with buffer and
jacket, the bending force is approximately 6.5.times.10.sup.4
dynes/cm of end deflection. For the flexible carrier to dominate
this force, the carrier should be designed to have a deflection
force of around 6.5.times.10.sup.5 dynes/cm.
[0107] For some coating and/or jacket materials, pre-annealing the
fiber ribbon cables (with or without a flexible carrier) in a
pre-bent configuration serves to decrease the changes that occur
over time in the force required for bending. In contrast, the glass
core and cladding is much more stable with time and the force
required for bending the glass core and cladding may not change
significantly over time. In some scenarios, pre-annealing the fiber
cables serves to shift the force required to maintain a bend in the
fiber ribbon cable from being predominantly dependent on the
coating and/or jacket, to being predominantly dependent on the
waveguide core. Consequently, the force required to further bend
the cable is decreased and the spring force of the cable is
controlled and is made more stable over time by the annealing. For
example, in some scenarios, the fiber cable can be installed in the
connector in a pre-bent configuration, wherein the pre-bending is
the same or about the same as the bending that occurs when two
connectors are mated. Before use, the fiber cable is annealed at
temperature in the pre-bent configuration. Annealing in the
pre-bent configuration can decrease the spring force contribution
due to the coating and jacket to less than about 50%, less than
about 40%, or even less than about 30% of the total spring force
applied to the light coupling unit by the optical fiber cable in
when the connector is mated with a mating connector. After
annealing, the glass core and cladding of the fiber can apply more
than about 50%, more than about 75%, more than about 90% or even
more than about 99% of the spring force applied to the light
coupling unit by the optical fiber cable when the connector is
mated with a mating connector. Vibration and/or mechanical shock to
the connector may cause vibration and/or movement of the light
coupling unit and the optical fiber cable (which are collectively
referred to herein as fiber-ferrule combination). One issue
associated with the use of the force from the waveguides or fibers
to control the motion of light coupling unit is the possibility of
unwanted motion of the light coupling unit due to vibration or
shock applied to the connector.
[0108] To reduce vibrations and/or to control the vibrational
resonant frequency of the fiber-ferrule combination, the flexible
first portion or the flexible second portion of a flexible carrier
can be or comprise a vibration dissipating material. In some
implementations, the vibration dissipating material can be selected
to decrease the amplitude of vibrations induced in the
fiber-ferrule combination and/or to change the resonant frequency
of the fiber-ferrule combination when compared to a fiber-ferrule
combination without the vibration dissipating material.
[0109] In one exemplary embodiment of the connector shown in FIGS.
6A and 6B, the optical waveguide 615 is a 12-fiber ribbon cable,
whose length between the first and second attachment areas is 1 cm.
With the light coupling unit 640 mounted on the end, the resonant
vibration frequency of the assembly is about 200 Hz. For some
applications, connectors experience vibrations in the range of 20
Hz to 2000 Hz. Therefore, dissipating vibrational energy and
avoiding resonance in this frequency range reduces the possibility
of the build-up of a potentially destructive resonant vibrational
amplitude. One approach to achieve dissipation of vibrational
energy is to fabricate the flexible carrier from a material that
has a large visco-elastic loss peak near the resonant frequency and
operating temperature. This can be implemented by fabricating the
flexible carrier using a polymeric material with a glass transition
temperature, Tg, near the operating temperature (80 C in the case
of many dense communications systems). In the case of the
fiber-ferrule combination having a flexible carrier as shown in
FIGS. 7A-7D, for example, at least a portion of either the flexible
first portion, 710, the flexible second portion, 720, or both, may
be fabricated of such a polymeric material. Examples of classes of
polymeric materials suitable for this application include
thermoplastic elastomers, block co-polymers, and composite
materials.
[0110] In some cases, the fiber-ferrule combination including the
flexible carrier having the vibration dissipating material may have
a resonant frequency greater than about 2,000 Hz. In some cases,
the addition of the vibration dissipating material to a
fiber-ferrule combination shifts the resonant frequency of the
fiber-ferrule combination from less than about 2,000 Hz to a
resonant frequency greater than about 2,000 Hz.
[0111] To render the connector resistant to shock, the
fiber-ferrule combination may be configured to resist rapid
bending, but to still conform easily for slow bending. Resistance
to rapid bending and compliance to slow bending can be achieved by
fabricating the flexible carrier at least partly of a visco-elastic
polymer material that has a strong viscous character to its
deformation vs. stress characteristics. The deformation of the
viscoelastic polymer is dependent on the rate of deformation which
causes the viscoelastic material to become stiffer when subjected
to a sheer force, for example. Again, the polymer should be used at
a temperature near its Tg to achieve sufficient visco-elastic
effect. Examples of classes of materials that can be suitable for
this application include thermoplastics such as urethanes, olefins,
acrylates, and ring-opening metathesis polymers. A specific example
of a material exhibiting this kind of behavior is DiARY MM3520 (SMP
Technologies, Tokyo, Japan), which is a commercially-available
thermoplastic polyurethane. At an ambient temperature of 29 C and a
stress rate of 15 N/min, the measured modulus of the sample is 2.5
times higher than the modulus at a stress rate of 0.5 N/min. In a
shock resistant version of the connector, a flexible carrier is
used, such as the flexible carrier illustrated in FIGS. 7A-7D,
wherein at least a portion of either the flexible first portion,
710, or the flexible second portion, 720, of the flexible carrier,
or both, may be fabricated of such a polymeric material.
[0112] For the connector of FIGS. 6A and 6B, for the case where the
waveguide consists of a 12-fiber cable with buffer and jacket, the
force applied normal to the fiber axis at the fiber end to cause
the end of a 1 cm long piece of cable to deflect by 1 mm is
4.9.times.10.sup.3 dynes. This corresponds to a bending moment of
4.9.times.10.sup.3 dyne cm.
[0113] In some embodiments, an attached flexible carrier can have a
significant effect on the bending of the structure. In these
embodiments, the bending force associated with the carrier is
comparable to, or greater than, that for the cable. In order for
the carrier to have no effect on the bending, then the bending
force contributed by the flexible carrier would be small compared
to that contributed by the fiber cable.
[0114] In some embodiments, the flexible carrier contributes to
some function of the flexible carrier (e.g. damping or shock
suppression), but does not significantly affect the bending force.
In these embodiments, the bending force of the flexible carrier
(that is, the addition to the bending force of the fiber cable)
would be significantly less than that of the cable.
[0115] In some embodiments, the flexible carrier is used to
significantly stiffen the fiber cable until a certain degree of
bending is accomplished. In these embodiment, the bending force
required to initially bend the cable and carrier assembly should be
significantly larger than to bend the cable alone, and once the
cable and carrier assembly is bent past a specified deflection, the
force should be comparable to that for the cable alone. In the case
of the 1 cm length of 12-fiber cable described above, this
functionality can be achieved by having the flexible first portion
of the flexible carrier have a very low bending force,
<<4.9.times.10.sup.3 dynes per 1 mm deflection, and the
flexible second portion have a bending force of
>>4.9.times.10.sup.3 dynes per 1 mm deflection for small
deflections less than a threshold value of the deflection, then
4.9.times.10.sup.3 dynes per 1 mm deflection, or less, for
deflections larger than the threshold deflection, e.g. 1 mm.
[0116] FIGS. 13 through 40 provide additional illustrations of
optical connectors and components thereof in accordance with
various embodiments. An optical ferrule (also referred to herein as
a light coupling unit) according to an embodiment of the present
disclosure is described below while referring to FIG. 13 through
FIG. 20. FIGS. 13 and 14 are perspective views illustrating a
configuration of an optical ferrule 1301 according to an embodiment
of the disclosure, and FIG. 15 is a perspective view illustrating
an example of using the optical ferrule 1301. Note that FIG. 15
illustrates a mated state of a pair of optical ferrules 1301 (1301A
and 1301B). The pair of optical ferrules 1301A and 1301B have the
same shape, and the optical ferrule 1301 is a male-female unit
(hermaphroditic) in the present embodiment.
[0117] As illustrated in FIG. 15, the end parts of a plurality of
optical fibers 1302 each exposed from a fiber ribbon 1303 (which is
a ribbon cable including a plurality of optical waveguides) are
fixed to the pair of optical ferrules 1301A and 1301B, and the tip
parts of the plurality of optical fibers 1302 (also referred to
herein as optical waveguides) are aligned and connected to each
other by the pair of optical ferrules 1301A and 1301B. Thereby,
light is transmitted in the direction of arrow A of FIG. 15 through
the first ferrule 1301A on the incoming light side and the second
ferrule 1301B on the outgoing light side. Note that below, the
front-back direction (length direction), the left-right direction
(width direction), and the vertical direction (thickness direction)
are defined as illustrated in FIGS. 13 and 14, and the
configuration of each part is described in accordance with these
definitions as a matter of convenience. The front-back direction is
the direction in which the optical fiber 1302 extends, and the
left-right direction is the direction in which the plurality of
optical fibers 1302 are arranged in parallel.
[0118] The optical fiber 1302 has a core and cladding, and assumes
a cylindrical shape with a predetermined outer diameter (for
example, 125 .mu.m). An ultraviolet curing resin (UV resin) or the
like is coated on the circumference of the optical fiber 1302, and
thus a fiber wire 1302a with a predetermined outer diameter (for
example, 250 .mu.m) is configured. The fiber ribbon 1303 is formed
by aligning the plurality of optical fiber wires 1302a and then
coating the entire circumference thereof with UV resin or the like,
and in FIG. 15, the fiber ribbon 1303a has four optical fiber wires
1302 arranged in four rows in the width direction. Note that the
assembly of the optical ferrule 1301 and the fiber ribbon 1303
including the optical fiber 1302 and optical fiber wires 1302a is
also referred to herein as an optical fiber unit 1400.
[0119] As illustrated in FIGS. 13 and 14, the optical ferrule 1301
has an upper wall 1310, a bottom wall 1311 on the opposite side of
the upper wall 1310, and a pair of side walls 1312 and 1313 on the
left and right, facing each other and connecting the upper wall
1310 and the bottom wall 1311, and the entire body assumes a
symmetrical shape. A rectangular guide opening 1314 passing through
in the front-back direction is formed on the inside of the upper
wall 1310, bottom wall 1311, and side walls 1312 and 1313. A guide
part 1315 that extends forward from the front end part of the guide
opening 1314 is provided on the upper wall 1310, and an optical
fiber coupler 1320 is provided on the upper surface of the upper
wall 1310.
[0120] The optical fiber coupler 1320 has an alignment part 1321
that serves as a part of the second attachment area. The alignment
part 1321 aligns and holds the optical fibers 1302. The optical
fiber coupler 1320 also includes a light direction converter 1322
which is also referred to as a light directing surface. FIG. 16 is
a view in the direction of arrow IV in FIG. 13, and FIG. 17 is a
cross-sectional view cut along line V-V in FIG. 16. As illustrated
in FIGS. 16 and 17, an expanded part 1402 that is wide in the
left-right direction from the center portion in the front-back
direction to the front end part is provided on an upper surface
1401 of the upper wall 1310. A first groove part 1403 of a
predetermined depth is provided on the rear end part of the
expanded part 1402, and a second groove part 1404 that is deeper
than the first groove part 1403 is provided in front of the first
groove part 1403. The light direction converter 1322 is provided in
front of the second groove part 1404.
[0121] V grooves 1405 in the same quantity as the optical fibers
1302 are formed in the left-right direction at equal intervals on
the bottom surface of the first groove part 1403. The depth of the
V grooves 1405 is shallower than the depth of the second groove
part 1404. The V grooves 1405 function as the alignment part 1321,
and the optical fibers 1302 are positioned by the V grooves 1405.
On the tip part of the fiber ribbon 1303, the coating of the fiber
ribbon 1303 and the coating of the fiber wires 1302a are removed,
and the optical fibers 1302 are exposed. The exposed optical fibers
1302 are placed in the V grooves 1404 in a state where the front
end part thereof is in contact with the rear end surface 1521 of
the light direction converter 1322. In this state, adhesive is
filled around the circumference of the optical fibers 1302, and the
optical fibers 1302 are fixed on the expanded part 1402 by the
adhesive. In the state where the optical fibers 1303 are placed and
fixed, the optical fibers 1302 are positioned lower than the upper
surface 1402a of both left and right end parts of the expanded part
1402. Therefore, the maximum height of the optical fiber unit 1400
that attaches the optical fibers 1302 to the optical ferrule 1301
is regulated by the expanded part 1402.
[0122] A rear end surface 1521 of the light direction converter
1322 is a vertical surface that extends in the vertical and
left-right directions, and forms an entrance surface that receives
incoming light from the optical fiber 1302 arranged by aligning
with the V grooves 1405, in other words, the incoming light in the
direction of arrow A in FIG. 17. A slanted surface 1522 that is
slanted at a predetermined angle (for example, 45 degrees) toward
the front is provided on the front end part of the light direction
converter 1322, and the slanted surface 1522 receives light from
the entrance surface 1521 and forms a light direction converting
surface that totally reflects the received light downward. A bottom
surface 1523 of the light direction converter 1322 below the light
direction converting surface 1522 is a flat surface that extends in
the front-back and left-right directions. The bottom surface 1523
receives light from the light direction converting surface 1522 and
forms an exit surface that emits the received light from the
optical ferrule 1301 downward (direction of arrow B).
[0123] Note that in FIG. 15, the optical ferrule 1301 was described
as a first optical ferrule 1301A (refer to FIG. 15) on the incoming
light side. In contrast, with the second optical ferrule 1301B on
the outgoing light side, the direction of movement is opposite from
the first optical ferrule 1301A, the bottom surface 1523 of the
optical ferrule 1 becomes an entrance surface, and the vertical
surface 1521 forms the exit surface. The entrance surface and the
exit surface are perpendicular to the incidence direction and
emission direction of the light.
[0124] FIG. 18 is a view in the direction of arrow VI in FIG. 13.
As illustrated in FIGS. 13, 14, and 18, a left and right pair of
first protruding parts 1453 and 1454 protruding upward and downward
extend in the front-back direction on the upper surface 1451 and
the bottom surface 1452 of the guide part 1315. The first
protruding part 1453 and first protruding part 1454 are positioned
in the same respective positions in the left-right direction. As
illustrated in FIG. 18, the first protruding parts 1453 and 1454
assume a cross-sectional rectangular shape, and the upper surface
of the first protruding part 1453 and the bottom surface of the
first protruding part 1454 are both flat surfaces.
[0125] As illustrated in FIG. 17 the first protruding parts 1453
and 1454 are both formed with a predetermined length rearward from
the front end part of the guide part 1315. The front end parts of
the first protruding parts 1453 and 1454 are formed with a tapered
shape, and a front end part 1355 of the guide part 1315 that is
more forward than the first protruding parts 1453 and 1454 is also
formed with a tapered shape. Therefore, the length from the upper
end surface of the first protruding part 1453 to the lower end
surface of the first protruding part 1454, in other words, a
maximum thickness t1 of the guide part 1315 is reduced toward the
front end surface of the guide part 1315.
[0126] As illustrated in FIGS. 16 and 17, a left and right pair of
second protruding parts 1407 and 1412 both protruding toward the
guide opening 1314 extend rearward on a bottom surface 1406 of the
upper wall 1310 and an upper surface 1411 of the bottom wall 1311
rearward of the guide part 1315. The second protruding part 1407
and the second protruding part 1412 are positioned in the same
respective positions in the left-right direction, and the positions
in the left-right direction match with the first protruding parts
1453 and 1454. As illustrated in FIG. 16, the second protruding
parts 1407 and 1412 assume a cross-sectional triangular shape, and
the cross-sectional area is reduced toward the guide opening
1314.
[0127] As illustrated in FIG. 17 the second protruding part 1412 on
the lower side is formed from the front end surface to the rear end
surface of the bottom wall 1311. On the other hand, the second
protruding part 1407 on the upper side is formed at a position more
forward than the front end surface of the bottom wall 1311 and more
rearward than the exit surface 1523 of the light direction
converter 1322 to the rear end surface of the upper wall 1310, and
the front end surface of the second protruding part 1407 is formed
with a tapered shape. The length from the bottom surface of the
second protruding part 1407 to the upper surface of the second
protruding part 1412, in other words, a minimum thickness t2 of the
guide opening 1314 is approximately equal to the maximum thickness
t1 of the guide part 1315.
[0128] As illustrated in FIG. 18, a length w1 in the left-right
direction of the guide part 1315 is approximately equal to a length
w2 in the left-right direction of the guide opening 1314. As
illustrated in FIG. 13, both left and right end surfaces of the
front end part of the guide 1315 are formed with a tapered shape,
and the width of the guide 1315 narrows toward the front. As
illustrated in FIGS. 14 and 17, the front end parts of the side
walls 1312 and 1313 protrude more forward than the bottom wall
1311, and the left and right inner wall surfaces of the protruding
parts 1421 and 1431 are formed with a tapered shape. Therefore, the
length of the interval between the left and right inner wall
surfaces of the protruding parts 1421 and 1431 that connect to the
guide opening 1314 increases toward the front. The front end
surfaces of the side walls 1312 and 1313 configure vertical
surfaces 1422 and 1432 that extend in the vertical and left-right
directions.
[0129] The aforementioned optical ferrule 1301 can use resin having
light transmissivity as a component and is integrally configured by
resin molding. In other words, the optical ferrule 1301 may be
configured by a single part. Therefore, the number of parts and
cost can be reduced.
[0130] The mating method of the pair of optical ferrules 1301A and
1301B will be described. FIG. 19A and FIG. 19B are a diagrams for
describing the mating method of the optical ferrules 1301A and
1301B. Note that the optical ferrules 1301A and 1301B are mated in
a state where the plurality of optical fibers 1302 are fixed to
each of the optical ferrules 1301A and 1301B in advance, but in
FIGS. 19A and 19B, an illustration of the optical fibers 1302 is
omitted.
[0131] First, as illustrated in FIG. 19A, the second optical
ferrule 1301B is inverted in the vertical direction relative to the
first optical ferrule 1301A, and the bottom surface 1452 of the
guide part 1315 of the first optical ferrule 1301A and the bottom
surface 1452 of the guide part 1315 of the second optical ferrule
1301B come into mutual contact. Next, while the guide part 1315 of
the second optical ferrule 1301B slides in the length direction
along the guide part 1315 of the first optical ferrule 1301A, the
guide part 1315 of the second optical ferrule 1301B is inserted
into the guide opening 1314 of the first optical ferrule 1A, and
the guide part 1315 of the first optical ferrule 1301A is inserted
into the guide opening 1314 of the second optical ferrule 1301B,
respectively.
[0132] The tip part of the guide part 1315 and the entrance part of
the guide opening 1314 are formed with a tapered shape in the
height direction and the thickness direction respectively, and
therefore, insertion of the guide part 1315 into the guide opening
1314 is simple. After the guide part 1315 is inserted, the first
protruding parts 1453 and 1454 (FIG. 18) of the guide part 1315 and
the second protruding parts 1407 and 1412 (FIG. 16) of the guide
opening 1314 come into mutual contact, and the first protruding
parts 1453 and 1454 slide on top of the second protruding parts
1407 and 1412. Therefore, the frictional force when inserting the
guide part 1315 is reduced, and the inserting force when mating the
first optical ferrule 1301A and the second optical ferrule 1301B
can be reduced. When the guide part 1315 is completely inserted
into the guide opening 1314, the first optical ferrule 1301A and
the second optical ferrule 1301B are in a mated state as
illustrated in FIG. 19B. In the mated state, the end part of the
guide part 1315 is positioned on the inner side of the guide
opening 1314 without protruding to the outside from the guide
opening 1314.
[0133] FIG. 20 is a perspective view illustrating the mated state
of the optical ferrules 1301A and 1301B. As illustrated in FIG. 20,
in the mated state, the vertical surfaces 1422 and 1432 of the side
walls 1312 and 1313 of the first optical ferrule 1301A, and the
vertical surfaces 1422 and 1432 of the side walls 1312 and 1313 of
the second optical ferrule 1301B come into mutual contact, and the
relative position in the length direction of the second optical
ferrule 1301B with regards to the first optical ferrule 1301A is
regulated. Furthermore, the maximum thickness t1 (FIG. 17) of the
first protruding parts 1453 and 1454 of the guide part 1315, and
the minimum height t2 of the second protruding parts 1407 and 1412
of the guide opening 1314 are approximately equal, and the relative
position in the height direction of the second optical ferrule
1301B with regards to the first optical ferrule 1301A is regulated.
Furthermore, the width w1 (FIG. 18) of the guide part and the width
w2 of the guide opening 1314 are approximately equal, and the
relative position in the width direction of the second optical
ferrule 1301B with regards to the first optical ferrule 1301A is
regulated.
[0134] By regulating the relative position in the length direction,
the height direction, and the width direction of the second optical
ferrule 1301B with regards to the first optical ferrule 1301A in
this manner, as shown in FIG. 19B, the bottom surface 1523 (exit
surface) of the first optical ferrule 1301A and the bottom surface
1523 (entrance surface) of the second optical ferrule 1301B can be
arranged facing each other with high positional accuracy.
[0135] FIG. 19B also illustrates the transmission path of the
light. The incoming light entering the first optical ferrule 1301A
from the optical fibers 1302 through the entrance surface 1521 is
propagated along an incoming axis L11, and is totally reflected by
the light direction converting surface 1522, thereby changing the
direction. The light with a change in direction is propagated along
an outgoing axis L12 for which the direction was converted, emitted
along an outgoing axis L13 from the exit surface 1523, and is
transmitted to the second optical ferrule 1301B as outgoing
light.
[0136] The light transmitted to the second optical ferrule 1301B
through the entrance surface 1523 is propagated along an incoming
axis L21, and is totally reflected by the light direction
converting surface 1522, thereby changing the direction. The light
with a change in direction is propagated along a direction
converted axis L22, emitted along an outgoing axis L23 from the
exit surface 1521, and is transmitted to the optical fibers 2 as
outgoing light. At this time, the outgoing axis L13 where the first
optical ferrule 1301A emits light and the incoming axis L21 where
the second optical ferrule 1301B receives light are the same axis,
and therefore, transmission loss of the light at the connection
surface of the optical ferrules 1301A and 1301B can be reduced.
[0137] The optical ferrule of the present embodiment can provide
the following effects. [0138] (1) The optical ferrule 1301
provides: an upper wall 1310; a bottom wall 1311; a pair of facing
side walls 1312 and 1313 that are connected to the upper wall 1310
and the bottom wall 1311 such that a guide opening 1314 is formed
on the inner side together with the upper wall 1310 and the bottom
wall 1311; a guide part 1315 (mechanical tab) that extends forward
from the upper wall 1310 and the guide opening 1314; and an optical
fiber coupler 1320 that is located on the upper surface of the
upper wall 1310. The optical fiber coupler 1320 has an alignment
part 1321 that aligns and hold the optical fibers 1302 and serves
as a first attachment area, and a light direction converter 1322.
The light direction converter 1322 has an entrance surface 1521 or
1523 that receives incoming light from the optical fibers 1302 that
are aligned and positioned by the alignment part 1321; a light
direction converting surface 1522 that receives the light
propagated along the incoming axis L11 or L21 from the entrance
surface 1521 or 1523, and then reflects the received light; and an
exit surface 1523 or 1521 that receives the light from the light
directing surface 1522, propagates the received light along the
outgoing axis L13 or L23, and then transmits the light as outgoing
light emitted from the optical ferrule 1301A or 1301B. The optical
ferrules 1301A and 1301B have a unitary structure.
[0139] Therefore, the optical ferrule 1301 does not require a
mating pin or mating hole that is required by some ferrules, and
also does not require installation space therefor. Therefore,
multi-fiber cables can be easily realized without increasing the
number of parts. [0140] (2) The pair of optical ferrules 1301A and
1301B that are mated together are male-female (hermaphroditic)
units. Therefore, the connectors have common parts, and the cost
can be reduced. [0141] (3) The optical ferrule 1301 provides: first
protruding parts 1453 and 1454 that protrude from the upper surface
1451 and the bottom surface 1452 of the guide part 1315, and extend
along the length direction of the optical ferrule 1301; and second
protruding parts 1407 and 1412 that protrude from the bottom
surface 1411 of the upper wall 1310 and the upper surface 1411 of
the bottom wall 1311, and extend along the length direction of the
optical ferrule 1301 toward the guide opening 1314. Therefore, of
the upper and lower surfaces of the guide part 1315 and the upper
and lower surfaces of the guide opening 1314, only the first
protruding parts 1453 and 1454 and the second protruding parts 1407
and 1412 are required to be processed with high accuracy, and thus
the processing cost can be reduced. [0142] (4) One of the optical
ferrules 1301A was made to mate along a mating direction parallel
to the length direction of the other optical ferrule 1301B, and
therefore, the optical fibers 1302 that extend in the length
direction of the optical ferrules 1301A and 1301B can be connected
in an approximately linear state. [0143] (5) The guide parts 1315
of the first optical ferrule 1301A and the second optical ferrule
1301B are both inserted on the inner side of the guide openings
1314 of the opposing first optical ferrule 1301A and second optical
ferrule 1301B respectively, and therefore, the first optical
ferrule 1301A and the second optical ferrule 1301B can be easily
mated. [0144] (6) When the first optical ferrule 1301A and the
second optical ferrule 1301B are mated, the first protruding parts
1453 and 1454 of the first optical ferrule 1301A and the second
optical ferrule 1301B are connected to the second protruding parts
1407 and 1412 of the opposing first optical ferrule 1301A and the
second optical ferrule 1301B so as to slide, and therefore, the
contact area of the guide part 1315 and the guide opening 1314 is
reduced, and insertion of the guide part 1315 into the guide
opening 1314 is easy. The first protruding parts 1453 and 1454 are
formed with a cross-sectional rectangular shape, and the second
protruding parts 1407 and 1412 are formed with a cross-sectional
triangular shape, and therefore, the guide part 1315 and the guide
opening 1314 are in linear contact at two left and right points,
and while the contact area is reduced, the guide part 1315 can be
stabilized and supported within the guide opening 1314.
[0145] Note that with the embodiment, the waveguide alignment part
(alignment part 1321) that aligns and contains the optical fibers
1302 as an optical waveguide is configured by the V grooves 1405,
but the configuration of the waveguide alignment part is not
restricted thereto. With the embodiment, the direction in which the
light reflected by the light direction converting surface 1322
propagates through the optical ferrule 1301 (direction of the
direction converted axis), and the direction that the outgoing
light is emitted from the optical ferrule 1301 (direction of the
outgoing axis) are the same, but as long as the reflected light is
propagated in a different direction than the direction that the
light that enters the optical ferrule 1301 is propagated (direction
of the incoming axis), the direction of the direction converted
axis can be different from the direction of the outgoing axis.
[0146] Next, the optical connector according to an embodiment is
described while referring to FIG. 21 through FIG. 40. FIG. 21 is a
perspective view illustrating the mated state of the optical
connectors (first optical connector 1305 and second optical
connector 1306) according to an embodiment. Note that below, the
front-back direction, the left-right direction, and vertical
direction are defined as illustrated by the drawings, and the
configuration of each part is described in accordance with these
definitions as a matter of convenience. The vertical direction is
the mating direction of optical connectors 1305 and 1306.
[0147] The first optical connector 1305 is attached to a first
substrate 1307 that extends in the front-back and left-right
directions, and the second optical connector 1306 is attached to a
second substrate 1308 that extends in the vertical and left-right
directions. A tip part of a plurality of optical fiber units 1400
(FIG. 15) that extend in the vertical direction, in other words, a
tip part of the optical fiber units 1400 having the aforementioned
first optical ferrule 1301A is disposed on the first optical
connector 1305. A tip part of the plurality of optical fiber units
1400 that extend in the vertical direction, in other words, a tip
part of the optical fiber units 1400 having the aforementioned
second optical ferrule 1301B is disposed on the second optical
connector 1306. When the first optical connector 1305 and the
second optical connector 6 are mated, the first optical ferrule
1301A and the second optical ferrule 1301B are mated, and the tip
parts of the optical fiber units 1400 on the first optical
connector side and the optical fiber units 1400 on the second
optical connector side are connected.
[0148] First, the configuration of the first optical connector 1305
is described. FIG. 22A and FIG. 22B are respective perspective
views of the first optical connector 1305. The first optical
connector 1305 has a first case 1350 that is attached to the first
substrate 1307 by passing through the first substrate 1307, and a
plurality of optical fiber assemblies 1351 that are housed in the
first case 1350. The optical fiber assemblies 1351 have four rows
of optical fiber units 1400 in the front-back direction, and four
rows of the optical fiber assemblies 1351 in the left-right
direction are disposed in the first case 1350.
[0149] FIG. 23A and FIG. 23B are each perspective views of the
optical fiber unit 1400. Note that the optical fiber units 1400 on
the first optical connector 1305 side and the optical fiber units
1400 on the second optical connector 1306 side have the same shape.
As illustrated in FIG. 23A and FIG. 23B, a securement member 1304,
that provides a portion of the first attachment area, is configured
by resin molding is fixed at a position that is separated only at a
predetermined distance from the optical ferrules (1301A and 1301B)
on one surface of a plurality of fiber ribbons 1303. The securement
member 1304 extends parallel to the width direction of the optical
ferrule 1301. A pair of receiving grooves 1342 are formed in the
width direction on a surface 1341 facing the fiber ribbons 1303 of
the securement member 1304, and engaging grooves 1343 that are
parallel with the receiving grooves 1342 are formed on both sides
in the width direction of the receiving grooves 1342. A pair of
fiber ribbons 1303 are contained in each of the receiving grooves
1342, and the fiber ribbons 1303 are fixed to the securement member
1304 by an adhesive. Another surface 1344 of the securement member
1304 is substantially flat.
[0150] As illustrated in FIG. 22A, the first case 1350 has a front
wall 1801, a rear wall 1802, and left and right side walls 1803 and
1804 that connect both left and right end parts of the front wall
1801 and both left and right end parts of the rear wall 1802, and
is made by resin molding. The front wall 1801, the rear wall 1802,
and the side walls 1803 and 1804 extend respectively in the
vertical direction, and the first case 1350 assumes a frame shape
where the upper surface and the lower surface are open. A holding
space SP10 for holding the optical fiber assemblies 1351 is formed
on the inner part of the first case 1350.
[0151] The first case 1350 has a center wall 1805 that connects the
left and right center part of the front wall 1801 and the left and
right center part of the rear wall 1802, and the holding space SP10
is divided in two in the left-right directions by the center wall
1805. A guide pin 1806 and a latch 1807 protrude upward on the
upper surface of the center wall 1805. The upper surface of the
center wall 1805 is positioned more downward than the upper
surfaces of the front wall 1801 and the rear wall 1802, and the
bottom surface of the center wall 1805 is positioned more upward
than the bottom surfaces of the front wall 1801 and the rear wall
1802. A cutaway is provided facing downward in the left-right
direction of the center part on the upper surface of the front wall
1801, and a concave part 1805a is formed by the cutaway on the
front side of the center wall 1805.
[0152] Collar parts 1808 and 1809 protruding to the outside in the
left-right direction of the center part in the front-back direction
are respectively provided on the left surface of the side wall 1803
and the right surface of the side wall 1804. An opening part 1370
corresponding to the external shape of the first case 1350 is
provided on the first substrate 1307, the lower end part of the
first case 1350 passes through the opening part 1370, and the
bottom surface of the first case 1350 protrudes more downward than
the bottom surface of the first substrate 1307. Screw holes 1371
and 1372 are formed around the opening part 1370. The screw hole
1371 is provided near the corner of the first case 1350, and the
screw hole 1372 is provided in front and behind the center wall
1805 of the first case 1350.
[0153] FIG. 24 is a cross-sectional view along line XIII-XIII of
FIG. 22B. As illustrated in FIG. 22B and FIG. 24, a slit 1800a is
provided on the bottom surface of the first case 1350, and a metal
plate 1800 is press fit in the slit 1800a. Note that in FIG. 22B,
an illustration of the right side of the plate 1800 is omitted. The
plate 1800 extends parallel to the opening of the bottom surface of
the first case 1350, and the front end part and the rear end part
of the opening of the bottom surface of the first case 1350 are
blocked by the plate 1800. A concave part 1800b is formed on the
upper surface of the plate 1800.
[0154] A metal supporting plate 1373 is attached to the bottom
surface of the first substrate 1307. The supporting plate 1373 is
fixed to the first substrate 1307 by a screw (not illustrated) that
screws into the screw hole 1371. The supporting plate 1373 has a
rectangular opening 2030, and the first case 1350 is disposed on
the inner side of the opening 2030. Respective rotating supporting
members 1374 are disposed in front and behind the center wall 1805
of the first case 1350. The rotating supporting member 1374 has a
flange part 2041 and an arm part 2042, and is made of resin
molding.
[0155] The flange part 2041 of the rotating supporting member 1374
is fixed to the first substrate 1307 with the supporting plate 1373
interposed therebetween by a screw (not illustrated) that is
screwed in the screw hole 1372. The arm part 2042 extends from the
flange part 2041 over the bottom surface of the first case 1350 to
the bottom surface of the center wall 1805. In other words, the arm
part extends such that the front and rear surfaces of the front
wall 1801 and the front and rear surfaces of the rear wall 1802 of
the first case 1350 are respectively interposed. A pin 2043 passes
through the front wall 1801 and the arm part 2042 of the rotating
supporting member 1374 on the front side, and passes through the
rear wall 1802 and the arm part 2042 of the rotating supporting
member 1374 on the rear side, in the front-back direction.
Therefore, the lower end part of the first case 1350 is supported
in a manner that can tilt from the first substrate 1307 with the
pin 2043 acting as a fulcrum.
[0156] Both left and right end parts of the supporting plate 1373
are bent downward away from the bottom surface of the first
substrate 1307 in the front-back direction of the center part, and
a spring shoe 2031 is fixed to the upper surface of the supporting
plate 1373. A coil spring (not illustrated) is interposed between
the spring shoe 2031 and the collar parts 1808 and 1809 of the
first case 1350. Therefore, the elastic force due to the coil
spring is applied to both left and right end parts of the first
case 1350 from the first substrate 1307 through the collar parts
1808 and 1809 and the supporting plate 1373, and the first case
1350 is elastically supported in a manner that can tilt from the
first substrate 1307 by a floating mechanism.
[0157] FIG. 25A and FIG. 25B are respective perspectives views of
the optical fiber assembly 1351 that is housed in the first case
1350. The optical fiber assembly 1351 contains: a left and right
pair of bodies 1352 that enclose four sets of optical fiber units
1400; a left and right pair of plate members 1353 that are
respectively fixed to the lower end parts of the left and right
pair of bodies 1352; and a front and rear pair of spring shoes 1354
that are attached to both front and rear end parts of the plate
members 1353. The body 1352 on the right side and the body 1352 on
the left side, as well as the plate member 1353 on the right side
and the plate member 1353 on the left side are symmetrical to each
other on the left and right. The spring shoe 1354 on the front side
and the spring shoe 1354 on the rear side can be symmetrical in the
front and back. The bodies 1352 and the spring shoes 1354 can be
made by resin molding. The plate member 1353 can be made of a metal
plate.
[0158] FIG. 26 is a view (plan view) in the direction of arrow XV
of FIG. 25A. As illustrated in FIG. 26, the body 1352 has a front
wall 1821, a rear wall 1822, and a side wall 1823 that connects the
front wall 1821 and the rear wall 1822, and assumes a C-shape from
a plan view. As illustrated in FIG. 25A, protruding parts 1824 and
1825 that protrude more upward than the side wall 1823 are formed
on the upper end part of the front wall 1821 and the upper end part
of the rear wall 1822. The protruding part 1824 has increased
thickness and rigidity toward the front. The protruding part 1824
protrudes further upward than the protruding part 1825 (refer to
FIG. 24).
[0159] FIG. 27A and FIG. 27B are respective perspective views that
omit the right side body 1352 from the optical fiber assembly 1351
of FIG. 25A and FIG. 25B, and FIG. 28 is a view (front surface
view) in the direction of arrow XVII of FIG. 27A. As illustrated in
FIG. 28, a protruding part 1826 that protrudes forward is provided
on the front surface of the front wall 1821 of the body 1352. An
engaging groove 1826a is formed on the circumference surface of the
protruding part 1826 (right end surface and lower end surface of
the protruding part 1826 of the body 1352 on the right side, and
the left end surface and the lower end surface of the protruding
part 1826 of the body 1352 on the left side). A U-shaped clip 1357
made from a metal plate of a predetermined thickness is engaged
from the lower side in the engaging grooves 1826a of the left and
right bodies 1352, and the front end parts of the left and right
bodies 1352 are connected through the clip 1357.
[0160] As illustrated in FIG. 26 and FIG. 27A, a protruding part
1827 that protrudes forward is provided on the front surface of the
rear wall 1822 of the body 1352. An engaging groove 1827a is formed
on the circumference surface of the protruding part 1827 (right end
surface and lower end surface of the protruding part 1827 of the
body 1352 on the right side, and the left end surface and the lower
end surface of the protruding part 1827 of the body 1352 on the
left side). A U-shaped clip 1358 made from a metal plate of a
predetermined thickness is engaged from the lower side in the
engaging grooves 1827a of the left and right bodies 1352, and the
rear end parts of the left and right bodies 1352 are connected
through the clip 1358. Therefore, as illustrated in FIG. 26, a
holding space SP11 of the optical fiber units 1400 is formed on the
inner side of the left and right bodies 1352. Note that the clip
1357 and the clip 1358 can have the same shape.
[0161] A plurality of position regulating parts 1828 that protrude
toward the holding space SP11 are provided at equal intervals in
the front back direction on the inner wall surface of the side wall
1823 of the body 1352. The front end surfaces (both left and right
end parts of the upper wall 1310 in FIG. 13) of the optical ferrule
1301 are respectively in contact with the position regulating part
1828, and a gap CL1 is provided between the rear end surface of the
optical ferrule 1301 and the position regulating part 1828 to the
back thereof. Thereby, the optical ferrule 1301 can be moved
rearward.
[0162] As illustrated in FIG. 27A, of the four rows of optical
fiber units 1400 in the front-back direction, the securement member
1304 is fixed on the rear end surface of the fiber ribbons 1303 for
the first and third rows of optical fiber units 1400a and 1400c,
and the securement member 1304 is fixed on the front end surface of
the fiber ribbons 1303 for the second and fourth rows of optical
fiber units 1400b and 1400d. Therefore, the flat surfaces 1344 of
the first and second rows of optical fiber units 1400a and 1400b
face each other, and the flat surfaces 1344 of the third and fourth
rows of optical fibers units 1400c and 1400d face each other.
[0163] A front and rear pair of grooves with bottoms 1831 and 1832
are formed facing downward on the upper end surface of the plate
member 1353. The end part of the securement members 1304 of the
optical ferrule units 1400a and 1400b, in other words, the engaging
groove 1343 in FIG. 23A is inserted from above into the groove with
bottom 1831 on the front side, and the engaging grooves 1343 of the
optical ferrule units 1400a and 1400b are respectively engaged in
the front wall and the rear wall of the groove with bottom 1831.
Similarly, the end parts (engaging groove 1343) of the securement
members 1304 of the optical ferrule units 1400c and 1400d are
inserted from above into the groove with bottom 1832 on the rear
side, and the engaging grooves 1343 of the optical ferrule units
1400c and 1400d are respectively engaged in the front wall and the
rear wall of the groove with bottom 1832. Thereby, the securement
members 4 of the optical ferrule units 1400a through 1400d are
fixed to the plate member 1353.
[0164] The plate member 1353 protrudes upward between the grooves
with bottom 1831 and 1832 and behind the groove with bottom 1832,
and through holes 1833 and 1834 are opened on the protruding part.
An illustration is omitted, but a convex part is provided
corresponding to the through holes 1833 and 1834 on the inner wall
surface of the side wall 1823 of the body 1352. The convex part of
the body 1352 is mated to the through holes 1833 and 1834 of the
left and right plate members 1353 from the outside on the left and
right, and the left and right bodies 1352 are fixed to the left and
right plate members 1353 by engaging the clips 1357 and 1358 from
below.
[0165] The front end part and the rear end part of the plate member
1353 protrude further forward and rearward than the front wall 1821
and the rear wall 1822 of the body 1352. Engaging grooves 1835 are
formed facing rearward and forward respectively on the front end
surface and the rear end surface of the protruding part. As
illustrated in FIG. 27B, circular concave parts 1840 are formed on
the left and right of the center part on the bottom surface of the
spring shoe 1354. A protruding part 1841 that protrudes in the
left-right direction corresponding to the engaging groove 1835 of
the plate member 1353 is provided on both left and right end parts
of the spring shoe 1354. The plate member 1353 and the spring shoe
1354 are integrated by engaging the protruding part 1841 of the
spring shoe 1354 from the outside in the left-right directions to
the groove with bottom 1835. Thereby, the optical fiber assemblies
1351 can be assembled.
[0166] As illustrated in FIG. 24, respective step parts 1350a are
provided on the rear surface of the front wall 1801 and the front
surface of the rear wall 1802 of the first case 1350, and the
length in the front-back direction of the holding space SP10 is
reduced on the upward side more than the step part 1350a. The
distance from the rear end surface of the step part 1350a on the
front side to the front end surface of the step part 1350a on the
rear side is equal to the distance from the front end surface to
the rear end surface of the body 1352 of the optical fiber assembly
1351. Therefore, the position in the front-back direction of the
body 1352 in the first case 1350 is regulated.
[0167] Note that an illustration is omitted, but respective step
parts 1350a are also provided on the right surface of the side wall
1803 and the left surface of the side wall 1804 of the first case
1305, and are joined to the step parts 1350a of the front wall 1801
and the rear wall 1802. The distance from the step part 1350a of
the side walls 1803 and 1804 to the left and right inner side
surfaces of the center wall 1805 is equal to the distance between
the left and right outer side surfaces of a pair of optical fiber
assemblies 1351 when the pair of optical fiber assemblies 1351 is
disposed on the left and right between the side walls 1803 and 1804
and the center wall 1805 as illustrated in FIG. 22A. Thereby, the
position in the left-right direction of the body 1352 in the first
case 1350 is regulated.
[0168] As illustrated in FIG. 24, a coil spring 1359 is interposed
between a concave part 1840 on the bottom surface of the spring
shoe 1354 of the optical fiber assembly 1351, and a concave part
1350b of a plate 1800 that is mounted on the bottom surface of the
first case 1350, and the optical fiber assembly 1351 can be raised
and lowered against the biasing force of the coil spring 1359. FIG.
24 illustrates a position of the optical fiber assembly 1351 after
mating the first optical connector 13015 to the second optical
connector 306, and the spring shoe 1354 is positioned lower than
the bottom surface 1350b of the step part 1350a. Before mating the
first optical connector 1305, the spring shoe 1354 is biased upward
by the spring 1359, and contacts the bottom surface 1350b of the
step part 1350a. Therefore, upward movement of the optical fiber
assembly 1351 is restricted, and the maximum raised position of the
optical fiber assembly 1351 in the first case 1350 is
regulated.
[0169] Next, the configuration of the second optical connector 1306
is described. FIG. 29A and FIG. 29B are perspective views of the
second optical connectors 1306. The second optical connector 1306
has a second case 60 attached to a second substrate 1308, and a
plurality of optical fiber assemblies 1361 that are housed in the
second case 1360. The optical fiber assemblies 1361 have four rows
of optical fiber units 1400 in the front-back direction, and four
rows of optical fiber assemblies 1361 are disposed in the
left-right direction in the second case 1360.
[0170] The second case 1360 has a front wall 1901, a rear wall
1902, and left and right side walls 1903 and 1904 that connect both
left and right end parts of the front wall 1901 and both left and
right end parts of the rear wall 1902, and is made by resin
molding. The front wall 1901, the rear wall 1902, and the side
walls 1903 and 1904 respectively extend in the vertical direction,
and the second case 1360 assumes a frame shape where the upper
surface and the lower surface are open. A holding space SP20 for
holding the optical fiber assemblies 1361 is formed on the inner
part of the second case 1360. A left and right pair of covers 1360a
are mounted on the upper surface of the second case 1360, and the
optical fiber unit 100 extends upward passing through the cover
1360a.
[0171] The second case 1360 has a center wall 1905 that connects
the left and right center part of the front wall 1901 and the left
and right center part of the rear wall 1902, and the holding space
SP20 is divided in two in the left-right directions by the center
wall 1905. A pin hole 1606 that engages the guide pin 1806 (FIG.
22A) of the first case 1350, and a latch hole 1907 that engages the
latch 1807 (FIG. 22A) are drilled in the lower surface of the
center wall 1905. Flange parts 1908 and 1909 protrude respectively
in the left and right directions on the rear end and upper end
parts of the side walls 1903 and 1904, and the second case 1360 is
fastened to the second substrate 1308 by a bolt that passes through
the flange parts 1908 and 1909.
[0172] A rectangular through hole 1360b is formed on the front wall
1901 and the rear wall 1902, corresponding to the position of
slanted parts 1367a and 1368a (FIG. 30A and FIG. 30B) of the clips
1367 and 1368 of the optical fiber assembly 1361. A long narrow
guide part 1910 with a constant width in the left-right direction
extends in the vertical direction to the front surface of the front
wall 1901. The lower end part of the guide part 1910 protrudes
further downward than the lower end surface of the front wall 1901
(refer to FIG. 33). The length in the front-back direction of the
lower end part of the outer wall surface of the second case 1360 is
shorter than the length in the front-back direction of the inner
wall surface above the first case 1350, and the length in the
left-right direction of the lower end part of the outer wall
surface of the second case 1360 is shorter than the length in the
left-right direction of the inner wall surface of the first case
1350.
[0173] Therefore, the second case 1360 can be inserted in the first
case 1350, and as illustrated in FIG. 21, when the lower end part
of the second case 1360 is inserted in the first case 1350, a guide
part 1910 of the second case 1360 is inserted in the concave part
1805a of the first case. At the same time, the guide pin 1806 of
the first case 1350 is inserted in the pin hole 1906 of the second
case 1360, and the second case 1360 is positioned in the first case
1350. Furthermore, the latch 1807 of the first case 1350 is engaged
in the latch hole 1907 of the second case 1360, and the second case
1360 is connected to the first case 1350.
[0174] FIG. 30A and FIG. 30B are respective perspective views of
the optical fiber assembly 1361 that is housed in the second case
1360. The optical fiber assembly 1361 contains: a left and right
pair of bodies 1362 that enclose four optical fiber units 1400; a
plate member 1363 that is fixed to the upper end part of the left
and right pair of bodies 1362; a plate spring member 1364 that is
supported on the rear end part of the left and right pair of bodies
1362; and a pressing member 1365 that is supported on the front end
part of the left and right pair of bodie 1362. The body 1362 on the
right side and the body 1362 on the left side are symmetrical to
each other on the left and right. The plate member 1363, the plate
spring member 1364, and the pressing member 1365 are symmetrical to
each other on the left and right. The body 1362 and the pressing
member 1365 can be made by resin molding. The plate member 1363 and
the plate spring member 1364 can be made of a metal plate.
[0175] FIG. 31 is a view (plan view) in the direction of arrow XX
of FIG. 30B. As illustrated in FIG. 31, the body 1362 has a front
wall 1921, a rear wall 1922, and a side wall 1923 that connects the
front wall 1921 and the rear wall 1922, and assumes a C-shape from
a plan view. As illustrated in FIG. 30B and FIG. 31, a protruding
part 1926 that protrudes forward is provided on the front surface
of the front wall 1921. An engaging groove 1926a is formed on the
circumference surface of the protruding part 1926 (right end
surface and lower end surface of the protruding part 1926 of the
body 1362 on the right side, and the left end surface and the lower
end surface of the protruding part 1926 of the body 1362 on the
left side). A U-shaped clip 1367 made from a metal plate of a
predetermined thickness is engaged downward in the engaging grooves
1926a of the left and right bodies 1362, and the front end parts of
the left and right bodies 1362 are connected through the clip 1367.
A slanted part 1367a that protrudes forward at a slant is provided
on both left and right end parts of the clip 1367.
[0176] As illustrated in FIG. 30A and FIG. 31, a protruding part
1927 that protrudes rearward is provided on the rear surface of the
rear wall 1922. An engaging groove 1927a is formed on the
circumference surface of the protruding part 1927 (right end
surface and lower end surface of the protruding part 1927 of the
body 1362 on the right side, and the left end surface and the lower
end surface of the protruding part 1927 of the body 1362 on the
left side). A U-shaped clip 1368 made from a metal plate of a
predetermined thickness is engaged downward in the engaging grooves
1927a of the left and right bodies 1362, and the rear end parts of
the left and right bodies 1362 are connected through the clip 1368.
A slanted part 1368a that protrudes rearward at a slant is provided
on both left and right end parts of the clip 1368. Therefore, as
illustrated in FIG. 31, the holding space SP21 of the optical fiber
units 1400 is formed on the inner side of the left and right bodies
1362. Note that the clip 1367 and the clip 1368 may have the same
shape.
[0177] A plurality of position regulating parts 1928 that protrude
toward the holding space SP21 are provided at equal intervals in
the front back direction on the inner wall surface of the side wall
1923 of the body 1362. The front end surface (both left and right
end parts of the upper wall 1310 in FIG. 21) of the optical ferrule
1301 are in contact with the position regulating part 1528, and a
gap CL2 is provided between the rear end surface of the optical
ferrule 1301 and the position regulating part 1928 to the back
thereof. Thereby, the optical ferrule 1301 can be moved rearward. A
partition wall 1929 protrudes in the left-right direction on the
inner side from the position regulating part 1928 of the foremost
part, and a holding space SP22 is formed between the partition wall
1929 and the front wall 1921. The pressing member 1365 is housed in
the holding space SP22.
[0178] FIG. 32A and FIG. 32B are respective perspective views that
omit the left side body 1362 from the optical fiber assembly 1361
of FIG. 31A and FIG. 31B. As illustrated in FIG. 32B, the
protruding part 1365a protrudes on both left and right end parts of
the pressing member 1365. As illustrated in FIG. 31, a stopper part
1929a is formed facing the upper end surface of the protruding part
1365a between the front wall 1921 and partition wall 1929 of the
body 1362. Upward movement of the pressing member 1365 is limited
due to the protruding part 1365a contacting the stopper 1929a.
[0179] As illustrated in FIG. 32A, the plate spring member 1364 has
a rectangular base part 1941, and an arm part 1942 that extends at
an angle forward and upward from the base part 1941, and an arc
shaped pressing part 1943 is formed on the tip of the arm part
1942. The arm part 1942 includes a pair of left and right beam
members for increasing the spring properties. Although an
illustration is omitted, a concave part that mates with the upper
and lower angle part of the right side and the upper and lower
angle part of the left side of the base part 1941 is formed in the
rear wall 1922 of the left and right bodies 1362. Therefore, when
the left and right bodies 1362 are joined, the angle part of the
base part 1941 mates with the concave part, and the base part 1941
is secured to the rear wall 1922. At this time, the pressing part
1943 of the plate spring member 1364 applies a bias in the forward
direction on the back end surface of the securement member 1304 of
the optical ferrule unit 1400. Therefore, as illustrated in FIG.
31, the optical ferrule 1301 is pushed forward, and contacts the
position regulating part 1928.
[0180] As illustrated in FIG. 32A and FIG. 32B, the plate material
1363 has left and right side walls 1931 and 1932 and a front wall
1933 that is connected to the front end part of the left and right
side walls 1931 and 1932. The lower end surfaces of the side walls
1931 and 1932 are provided with grooves with bottoms 1935 and 1936
similar to the optical fiber assembly 1351 (FIG. 27A) of the first
optical connector 1305. The engaging groove 1343 of the securement
member 1304 of the optical ferrule unit 1400 (FIG. 23B) engages
with the front wall and the rear wall of the grooves with bottoms
1935 and 1936, and the securement member 1304 of the optical
ferrule unit 1400 is secured to the plate member 1363. A front and
back pair of semicircular shaped protruding parts 1937 are provided
on the upper end surface of the side walls 1931 and 1932. A slanted
part 1934 that slants upward and backward extends from the upper
end surface of the front wall 1933 of the plate member 1363. A
lower end surface of a pressing member 1365 abuts the upper surface
of the slanted part 1934.
[0181] The plate member 1363 protrudes upward between the grooves
with bottoms 1931 and 1932, and an elongated hole 1933 elongated in
the front and back direction is formed in the protruding part. A
convex part 1925 (FIG. 33) corresponding to the elongated hole 1933
is provided in the side wall surface of the side wall 1923 of the
body 1362. The height in the vertical direction of the convex part
1925 is almost equal to the height of the elongated hole 1933, and
the length in the front back direction of the convex part 1925 is
shorter than the length of the elongated hole 1933. When the left
and right bodies 1362 are linked by clips 1367 and 1368, the convex
part 1925 of the body 1362 mates with the elongated holes 1933 of
the left and right plate members 1363 from the outer sides in the
left and right direction. The concave part 1925 can slide in the
front and back direction along the elongated hole 1933, and
therefore the left and right bodies 1362 are connected so as to be
moveable in the front and back direction to the plate member 1363.
Thereby the optical fiber assembly 1361 is assembled.
[0182] FIG. 33 is a cross-section view cut along line XXII-XXII in
FIG. 29A. As illustrated in FIG. 33, step parts 1901a and 1902a are
provided on the front surface of the rear wall 1902 and the back
surface of the front wall 1901 of the second case 1360, and the
length in the front and back direction of the holding space SP20 is
narrower toward the bottom of the step parts 1901a and 1902a. When
the optical fiber assembly 1361 is inserted from above the second
case 1360, the lower end surface of the protruding parts 1926 and
1927 will abut the upper surface of the step parts 1901a and 1902a,
and thus downward movement of the optical fiber assembly 1361 is
limited. At this time, the tips of the slanted parts 1367a and
1368a of the clips 1367 and 1368 are inserted into the opening part
1360b (FIG. 29B) of the optical connectors 1360, and thus upward
movement of the optical fiber assembly 1361 is also limited.
[0183] The length from the front end surface to the back end
surface of the body 1362 of the optical fiber assembly 1361 is
equal to the length from the back surface of the front wall 1901 to
the front surface of the rear wall 1902 of the second case 1360
above the step parts 1901a and 1902a. Thereby, the position of the
body 1362 in the second case 1360 is regulated. In this case, the
convex part 1925 of the body 1362 mates with the elongated hole
1933 in the front and back direction of the plate member 1363, and
the plate member 1363 can move back against the biasing force of
the plate spring member 1364 while the protruding part 1937 of the
upper end surface of abuts the bottom surface of the cover 1360a.
Note that as illustrated in FIG. 29A, when the pair of optical
fiber assemblies 1361 is positioned between the side walls 1903 and
1904 and the center wall 1905 of the second case 1360, the distance
between the left and right outer side surfaces of the pair of
optical fiber assemblies 1361 is equal to the distance from the
left right inner side surfaces of the side walls 1903 and 1904 of
the second case 1360 to the center wall 1305. Therefore, the
position in the left and right direction of the body 1362 in the
second case 1360 is regulated.
[0184] The action when mating the optical connectors 1305 and 1306
will be described. For example, when the second optical connector
1306 is pressed to the first optical connector 1305, the position
is determined by the guide pin 1806 (FIG. 22A) and the guide part
1910 (FIG. 29A), while at the same time, as illustrated in FIG. 34,
the protruding part 1824 on the front wall upper end part of the
body 1352 of the first optical connector 1305 is inserted into the
holding space SP22 of the back part of the front wall of the body
1362 of the second optical connector 1306, and the tip of the
protruding part 1824 contacts the lower end part of the pressing
member 1365. When the second optical connector 1306 is pressed
further, the protruding part 1824 presses the pressing member 1365
upward, and thus a pushing force in the back direction is applied
to the plate member 1363 through the slanted part 1934. Therefore,
the plate member 1363 moves rearward against the biasing force of
the plate spring member 1364, and in conjunction, the securement
member 1304 of the optical fiber unit 1400 is also moved
rearward.
[0185] The first optical ferrule 1301A can move in the front and
back direction in the holding space SP11 of the body 1352, and the
second ferrule 1301B can move in the front and back direction in
the holding space SP21 of the body 1362. As a result, the mating
profile between the first optical ferrule 1301A that is assembled
into the first optical connector 1305 and the second optical
ferrule 1301B that is assembled into the second optical connector
1306 will be at a slant. In other words, the first optical ferrule
1301A and the second optical ferrule 1301B mutually extend in the
vertical direction and begin to mate, but as mating progresses, the
securement member 1304 on the second optical ferrule 1301B side
will move rearward, and the optical ferrule unit 1400 (fiber ribbon
1303) will become a point of support for the securement member 1304
and will deform (bend), and thus the first optical ferrule 1301A
and the second optical ferrule 1301B will slant while maintaining
the mating profile (first slant). Even if the first optical ferrule
1301A and the second optical ferrule 1301B are completely mated,
the second optical connector 1306 will be pressed until the latch
1807 of the first optical connector 1305 engages with the latch
hole 1907 of the second optical connector 1306, the optical ferrule
unit 1400 will further deform as a point of support for the
securement member 1304, and the first optical ferrule 1301A and the
second optical ferrule 1301B will slant further while maintaining
the mating profile (second slant).
[0186] In this manner, an elastic force (reaction force of
deformation) acts in a direction that pushes the first optical
ferrule 1301A and the second optical ferrule 1301B together because
the optical ferrule unit 1300 is deformed by the first slant and
the second slant of the optical ferrules 1301A and 1301B.
Therefore, stable light transmission characteristics can be
maintained between the optical ferrules 1301A and 1301B, even with
the effects of vibration and the like. In this case, the optical
connectors 1305 and 1306 are pressed while the optical ferrules
1301A and 1301B are slanting, so the mating force of the optical
connectors 1305 and 6130 can be reduced. In other words, when the
optical connectors 1305 and 1306 are mated in a condition where the
optical ferrules 1301A and 1301B are not slanted, an extremely
large force will act in order to bend the optical ferrule unit
1400. In contrast, with the present embodiment, the optical
connector is mated while the optical ferrule is slanted, and thus
the force that bends the optical ferrule unit 1400 can be
reduced.
[0187] Furthermore, with the present embodiment in the initial
condition, the optical ferrules 1301A and 1301B the mating
direction of the optical connectors 1305 and 1306 and the mating
direction of the optical ferrules 1301A and 1301B are the same, and
thus the optical ferrules 1301A and 1301B can easily be aligned. In
contrast, if the optical ferrules 1301A and 1301B are not slanted
from the beginning, the mating direction of the optical ferrules
1301A and 1301B will not match the mating direction of the optical
connectors 1305 and 1306, and therefore the aligning of the optical
ferrules 1301A and 1301B will be difficult.
[0188] With the present embodiment, the center part in the left and
right direction of the first case 1350 is supported so as to be
able to tilt with regards to the first substrate 1307 by a pin 2043
that extends in the front and back direction, and both end parts in
the left and right direction of the first case 1350 are elastically
supported by the first substrate 1307 via a coil spring. In other
words, the first case 1350 is supported by the first substrate 1307
through a floating mechanism. Therefore, positional shifting can be
absorbed when mating the optical connectors 1305 and 1306, and thus
the mating operation is easy.
[0189] The effect of the aforementioned action of the optical
connectors 1305 and 1306 is described using conceptual diagrams.
FIG. 35 and FIG. 36 are diagrams conceptually illustrating an
initial mating state and a final mating state of the optical
connectors 1305 and 1306. As illustrated in FIG. 35, in the initial
mating state, the mating direction of the first optical connector
1305 and the second optical connector 1306 matches the mating
direction of the first optical ferrule 1301A and the second optical
ferrule 1301B. As illustrated in FIG. 36, in the final mating
state, the pressing member 1365 is pressed by the protruding part
1824 of the body 1352, and the securement member 1304 moves in the
direction of arrow A, or in other words in the perpendicular
direction with regards to the mating direction of the optical
connectors 1305 and 1306, together with the plate member 1363
against the spring force of the plate spring member 1364.
Therefore, the optical ferrules 1301A and 1301B slant relative to
the mating direction of the optical connectors 1305 and 1306, and
the fiber ribbon 1303, or in other words the optical fiber 1302 is
deformed (bent), and thus a force that causes mutual contact acts
on the contact surfaces of the optical ferrules 1301A and
1301B.
[0190] FIG. 37 is a diagram illustrating a modified example of FIG.
35. In FIG. 37, an elastic reinforcing member 1303a is attached to
the optical ferrules 1301A and 1301B and the fiber ribbon 1303.
Therefore, even if the optical connectors 1305 and 1306 are used
for a long period of time and the elastic force of the fiber ribbon
1303 is reduced, a stable contact force can be maintained between
the optical ferrules 1301A and 1301B, and the durability of the
optical connectors 1305 and 1306 can be enhanced. The
cross-sectional shape of the elastic reinforcing member 1303a in
this case can be a variety of shapes. For example, a semicircular
curve shape is acceptable. Note that the elastic reinforcing member
1303a can be attached to only the optical ferrule 1301 or to only
the fiber ribbon 1303.
[0191] FIG. 38 is a diagram illustrating a modified example of FIG.
36. In FIG. 38, the protruding part 1824 of the body 1352 also acts
as a guide pin, and thus the guide pin 1806 is omitted. The
protruding part 1824 abuts the slanted part 1934 of the plate
member 1363, and moves the plate member 1363 in the direction of
arrow A without using the pressing member 1365. Furthermore, in
FIG. 38, the plate member 1830a of the optical connector 1305 is
provided so as to be able to slide, similar to optical connector
1306, and thus a new plate spring member 1840a is provided.
Furthermore, a protruding part 1924 similar to that of the optical
connector 1305 is provided on the body 1362 of the optical
connector 1306. Therefore, when the optical connectors 1305 and
1306 are mated, the plate member 1363 moves in the direction of
arrow A, and the plate member 1830a moves in the direction of arrow
B that is opposite the direction of arrow A. In other words, both
of the plate members move in opposite directions. In this design,
the connectors 1305 and 1306 may be identical, yet still mate to
each other; that is, the connectors are hermaphroditic.
[0192] Note that in the example of FIG. 36, similar to FIG. 38, the
protruding part 1824 extends in the longitudinal direction, and
thus the guide pin 1806 and the pressing member 1365 can be
omitted. Furthermore, similar to FIG. 38, a configuration where the
plate member 1353 can slide is also possible.
[0193] FIG. 39 is a diagram illustrating another modified example
of FIG. 36. In FIG. 39, angle members 1305b and 1306b are provided
on the bodies 1352 and 1362 of the optical connectors 1305 and
1306, and the fiber ribbon 1303 extends at a predetermined angle
with regards to the mating direction of the optical connectors 1305
and 1306. Furthermore, guide parts 1305C and 1306C that prevent
tilting of the optical ferrules 1301A and 1301B are provided in the
area of the optical ferrules 1301A and 1301B. In other words, FIG.
39 illustrates a configuration where a bend occurs in the fiber
ribbon 1303 prior to mating. Note that in FIG. 39, a guide pin
1306d protrudes from the optical connector 1306 side, but this can
be omitted.
[0194] FIG. 40 is a diagram illustrating another modified example
of FIG. 35. In FIG. 37, the securement member 1304 is secured to
the inner side of the bodies 1352 and 1362, and the fiber ribbon
1303 extends in the mating direction of the connectors 1305 and
1306 at the securement part. Guide parts 1305e and 1306e that
movably support the optical ferrules 1301A and 1301B in the mating
direction of the optical connectors 1305 and 1306 are provided on
the bodies 1352 and 1362. The guide positions of the optical
ferrules 1301A and 1301B are shifted in a direction perpendicular
to the mating direction of the connectors 1305 and 1306 with
regards to the securing position of the securement member, and in
FIG. 40, the fiber ribbon 1303 has a slight S-shaped curve. When
the optical connector 1306 is mated to the optical connector 1305
from this state, the tip part (attaching part to the optical
ferrules 1301A and 1301B) of the optical fiber 1303 will move in
the bodies 1352 and 1362 along the mating direction of the
connectors 1305 and 1306. Through this, the bend in the fiber
ribbon 1303 is increased, and the abutting force of the optical
ferrules 1301A and 1301B is increased. Note that the optical fiber
ribbon 1303 in connector 1306 can be in an unbent state prior to
mating to the optical connector 1305. The direction of deformation
of the fiber ribbon 1303 and the optical fiber 1302 in FIGS. 36,
38, 27, and 40 is one example, but it is also possible for the bend
to be in the opposite direction from that illustrated.
[0195] Note that in the above-described embodiment (FIG. 35), the
optical connector 1306 is provided with a securement member 1304,
or in other words a first attaching region, that holds and retains
the fiber ribbon 1303 as the optical waveguide, and moves in the
housing of the body 1362 or the like, and with an optical coupler
part provided in the housing, and that moves in the housing. In
other words, the optical coupler part has a second attaching
region, or in other words a V groove 1405, that holds and retains
the optical waveguide that is held and retained in the first
attaching region, and a light direction converting surface 1522
that changes the direction of the light received from the optical
waveguide when the optical waveguide is held and retained in the
first attaching region and the second attaching region, and
therefore when the connector 6 mates with the opposing connector
1305, the first attaching region will move, causing the optical
coupler part to move. In the above-described embodiment, the second
attaching region was described as the optical ferrule 1301, but in
a more precise sense, it is the region where the optical fiber 1302
is attached to the optical ferrule 1301.
[0196] The housing can have any configuration so long as when the
optical wave guide is held and retained by the first attaching
region and the second attaching region, and the connector is mated
to the opposing connector, the first attaching region moves causing
the optical waveguide to move while the optical coupler part is
also caused to move. The configuration of the first attaching
region and the second attaching region is not restricted to the
aforementioned configuration. In the above-described embodiment,
the first attaching region is primarily moved laterally and the
optical coupler part is primarily moved rotationally (tilted) when
the optical waveguide is held and retained in the first attaching
region and the second attaching region and the connector is mated
to the opposite connector, but the movement of the first attaching
region and the second attaching region is not restricted
thereto.
[0197] In the embodiment, when the optical waveguide was held and
retained by the first attaching region and the second attaching
region, and the connector was mated to the opposite connector, the
first attaching region moved along the direction orthogonal to the
mating direction of the connector, but a portion of the first
attaching region may also move. The optical coupler part of the
above-described embodiment was stably supported in the housing by
the optical waveguide being held and retained by the first
attaching region and the second attaching region, however, the
optical coupler part may be stably supported in the housing due at
least to the optical waveguide being held and retained by the first
attaching region and the second attaching region, or due only to
the optical waveguide being held and retained by the first
attaching region and the second attaching region.
[0198] The embodiments can be described from various perspectives.
For example, in the example of FIG. 35, when the connector 1306 is
mated to the opposing connector 1305, the first attaching region
(securement member 1304) and the second attaching region (optical
ferrule 1301) will move and cause the bend of the optical waveguide
(fiber ribbon 1303) to increase. In this case, the optical
waveguide is not bent before the connector 1306 is mated to the
opposing connector 1305. When the connector 1306 is mated to the
opposing connector 1305, the first attaching region moves in a
direction essentially perpendicular to the mating direction of the
connector 1306, and the second attaching region moves in a
direction that is essentially parallel to the mating direction of
the connector 1306.
[0199] Embodiments discussed in this disclosure include at least
the following items: [0200] Item 1. A connector comprising a
housing comprising: [0201] a first attachment area for receiving
and permanently attaching to an optical waveguide; and [0202] a
light coupling unit disposed and configured to move translationally
and not rotationally within the housing and comprising: [0203] a
second attachment area for receiving and permanently attaching to
an optical waveguide received and permanently attached at the first
attachment area; and [0204] a light redirecting surface configured
such that when an optical waveguide is received and permanently
attached at the first and second attachment areas, the light
redirecting surface receives and redirects light from the optical
waveguide, and the optical waveguide limits, but does not prevent,
a movement of the light coupling unit within the housing. [0205]
Item 2. The connector of item 1, wherein the first attachment area
is fixed within the housing. [0206] Item 3. The connector of item
1, wherein the first attachment area is configured to move within
the housing. [0207] Item 4. The connector of any of items 1 through
3, wherein when an optical waveguide is received and permanently
attached at the first and second attachment areas, a mating of the
light coupling unit with a mating light coupling unit of a mating
connector causes a bend in the optical waveguide between the first
and second attachment areas, the bend assisting in preventing the
light coupling unit from unmating from the mating light coupling
unit. [0208] Item 5. The connector of item 4, wherein the bend
comprises a further bend in an existing bend. [0209] Item 6. The
connector of any of claims 1 through 5, wherein when an optical
waveguide is received and permanently attached at the first and
second attachment areas, a mating of the light coupling unit with a
mating light coupling unit of a mating connector causes the second
attachment area to move within the housing causing a bend in the
optical waveguide, the bend assisting in preventing the light
coupling unit from unmating from the mating light coupling unit.
[0210] Item 7. The connector of item 6, wherein after the mating,
the optical fiber applies a spring force to the light coupling unit
to maintain the light coupling unit in a mating position with
respect to a mating light coupling unit. [0211] Item 8. The
connector of any of items 1 through 7, wherein the housing further
comprises at least one guide for preventing the light coupling from
rotating, but not moving translationally, within the housing.
[0212] Item 9. The connector of item 8, wherein the at least one
guide is disposed adjacent to and facing at least one of a top and
a bottom major surface of the light coupling unit. [0213] Item 10.
The connector of any of items 1 through 9, wherein the housing
comprises a pair of guides, one guide of the pair of guides on each
side of the light coupling unit, the pair of guides configured to
prevent the light coupling unit from rotating, but not
translationally moving, within the housing. [0214] Item 11. The
connector of item 10, wherein one guide of the pair of guides is
disposed adjacent to and facing a top major surface of the light
coupling unit, and another guide of the pair of guides is disposed
adjacent to and facing a bottom major surface of the light coupling
unit. [0215] Item 12. The connector of any of items 1 through 11,
further comprising a registration feature configured to engage with
a compatible mating feature of a mating connector. [0216] Item 13.
The connector of item 12, wherein the registration feature
comprises an elongated protrusion and the compatible mating feature
comprises an elongated channel. [0217] Item 14. The connector of
any of items 1 through 13, wherein the light redirecting surface
comprises a curved surface, the optical waveguide having a first
core diameter, the curved surface being configured to change a
divergence of light from the optical waveguide such that light from
the optical waveguide exits the connector along an exit direction
different than a mating direction of the connector and having a
second diameter greater than the first core diameter. [0218] Item
15. The connector of any of items 1 through 14, wherein the light
coupling unit includes a first alignment feature and a second
alignment feature, during mating of the light coupling unit with a
mating light coupling unit, the first alignment feature is
configured to engage with a mating second alignment feature of the
mating light coupling unit and the second alignment feature is
configured to engage with a mating first alignment feature of the
mating light coupling unit. [0219] Item 16. The connector of item
15, wherein the first alignment feature comprises a tab and the
second alignment feature comprises a guide hole. [0220] Item 17.
The connector of item 16, wherein the guide hole comprises a first
end and a second end, during mating of the light coupling unit and
the mating light coupling unit, the first end of the guide hole
engaging with a mating tab of the mating light coupling unit before
the second end of the guide hole engages with the mating tab of the
mating light coupling unit, and wherein the first end of the guide
hole includes a taper that causes the guide hole to become narrower
with distance from the first end for at least a portion of a length
of the guide hole. [0221] Item 18. The connector of any of claims 1
through 17, wherein the optical waveguide comprises a pre-bent,
annealed optical waveguide. [0222] Item 19. The connector of any of
items 1 through 18, wherein the optical waveguide is one of a
plurality of optical waveguides in an optical fiber ribbon cable,
each optical waveguide in the optical fiber ribbon cable comprises
a core, a cladding, and a coating, the optical fiber ribbon cable
comprising a jacket disposed over the plurality of optical
waveguides, wherein a spring force of the core and cladding of the
plurality of optical waveguides is in the optical fiber ribbon
cable is greater than a spring force of the the coatings and jacket
of the optical fiber ribbon cable when the connector is mated with
a mating connector. [0223] Item 20. A connector comprising a
housing comprising: [0224] a first attachment area for receiving
and permanently attaching to an optical waveguide and configured to
move within the housing; and [0225] a light coupling unit disposed
and configured to move within the housing and comprising: [0226] a
second attachment area for receiving and permanently attaching to
an optical waveguide received and permanently attached at the first
attachment area; and [0227] a light redirecting surface configured
such that when an optical waveguide is received and permanently
attached at the first and second attachment areas, the light
redirecting surface receives and redirects light from the optical
waveguide, and the optical waveguide limits, but does not prevent,
a movement of the light coupling unit within the housing. [0228]
Item 21. The connector of item 20, wherein the optical waveguide
limits, but does not prevent, the movement of the light coupling
unit within the housing primarily along a linear direction. [0229]
Item 22. The connector of any of items 20 through 21, wherein the
optical waveguide limits, but does not prevent, the movement of the
light coupling unit within the housing primarily along a connector
mating direction of the connector. [0230] Item 23. The connector of
any of items 20 through 22, wherein in the absence of any optical
waveguide received and permanently attached at the first and second
attachment areas, the light coupling unit is unrestrained to move
freely along at least one direction. [0231] Item 24. The connector
of any of items 20 through 23, wherein in the absence of any
optical waveguide received and permanently attached at the first
and second attachment areas, the light coupling unit is loose
within the housing and free to move along at least one direction.
[0232] Item 25. The connector of any of items 20 through 24,
wherein the light coupling unit is stably supported within the
housing, at least in part, by virtue of an optical waveguide being
received and permanently attached at the first and second
attachment areas. [0233] Item 26. The connector of any of items 20
through 25, wherein when an optical waveguide is received and
permanently attached at the first and second attachment areas, the
optical waveguide is substantially unbent between the first and
second attachment areas. [0234] Item 27. The connector of item 20,
wherein when an optical waveguide is received and permanently
attached at the first and second attachment areas, the optical
waveguide is bent between the first and second attachment areas.
[0235] Item 28. The connector of any of items 20 through 27,
wherein the light coupling unit is configured to be so positioned
and oriented within the housing as to mate with a light coupling
unit of a mating connector as the connector mates with the mating
connector, the light coupling unit being so positioned and
oriented, at least in part, by virtue of an optical waveguide being
received and permanently attached at the first and second
attachment areas. [0236] Item 29. The connector of any of items 20
through 28, wherein when an optical waveguide is received and
permanently attached at the first and second attachment areas, a
mating of the light coupling unit with a mating light coupling unit
of a mating connector causes a bend in the optical waveguide
between the first and second attachment areas, the bend assisting
in preventing the light coupling unit from unmating from the mating
light coupling unit. [0237] Item 30. The connector of item 29,
wherein the bend comprises a further bend in an existing bend.
[0238] Item 31. The connector of item 30, wherein the existing bend
comprises an S-shaped bend. [0239] Item 32. The connector of any of
items 20 through 31, wherein when an optical waveguide is received
and permanently attached at the first and second attachment areas,
a mating of the light coupling unit with a mating light coupling
unit of a mating connector causes the first attachment area to move
within the housing, causing a first bend in the optical waveguide,
the light coupling unit to move within the housing, and a second
bend in the optical waveguide, the second bend assisting in
preventing the light coupling unit from unmating from the mating
light coupling unit. [0240] Item 33. The connector of item 32,
wherein the first bend comprises a further bend in an existing
bend. [0241] Item 34. The connector of item 32, wherein the second
bend comprises a further bend in the first bend. [0242] Item 35.
The connector of any of items 32 through 34, wherein the first
attachment area moves in a direction substantially perpendicular to
a connector mating direction of the connector and the light
coupling unit moves substantially parallel to the connector mating
direction toward the first attachment area. [0243] Item 36. The
connector of any of items 32 through 35 comprising a registration
feature, such that as the connector mates with a mating connector
along a mating direction, the registration feature of the connector
mates with a registration feature of the mating connector, the
registration feature of the mating connector causing the first
attachment area of the connector to move within the housing of the
connector. [0244] Item 37. The connector of item 36, wherein the
registration feature of the connector defines an elongated channel
and the registration feature of the mating connector comprises an
elongated protrusion, such that as the connector mates with the
mating connector, the elongated protrusion slides within the
channel, a front end of the elongated protrusion sliding past the
channel and making contact with the first attachment area, the
contact causing the first attachment area to move within the
housing of the connector. [0245] Item 38. The connector of any of
items 20 through 37, wherein the housing further comprises at least
one guide for preventing the light coupling from rotating, but not
moving translationally, within the housing. [0246] Item 39. The
connector of item 38, wherein the at least one guide is disposed
adjacent to and facing at least one of a top and bottom major
surfaces of the light coupling unit. [0247] Item 40. The connector
of any of items 20 through 39, wherein the housing comprises a pair
of guides, one on each side of the light coupling unit, for
preventing the light coupling unit from rotating, but not
translationally moving, within the housing. [0248] Item 41. The
connector of item 40, wherein one guide in the pair of guides is
disposed adjacent to and facing a top major surface of the
connector, and the other guide in the pair of guides is disposed
adjacent to and facing a bottom major surface of the light coupling
unit. [0249] Item 42. The connector of any of claims 20 through 41,
wherein during mating with a mating connector, the first attachment
area is configured to move in a first direction and the light
coupling unit is configured to move in a second direction different
from the first direction. [0250] Item 43. The connector of item 42,
wherein the second direction is along a mating direction of the
connector. [0251] Item 44. The connector of item 43, wherein the
first direction is substantially orthogonal to the mating
direction. [0252] Item 45. The connector of any of items 20 through
44, wherein the first attachment feature comprises a contact
surface configured to cause movement of the first attachment
feature during mating of the connector to a mating connector as a
registration feature of the mating connector engages with the
contact surface. [0253] Item 46. The connector of item 45, wherein
the contact surface is a ramp. [0254] Item 47. The connector of any
of items 45 through 46, wherein the first attachment feature
includes a stop feature configured to limit movement of the
registration feature of the mating connector. [0255] Item 48. The
connector of any of items 20 through 47, further comprising at
least one compressible element, wherein movement of the first
attachment area causes the compressible element to apply spring
force in a direction opposing a direction of movement of the first
attachment area. [0256] Item 49. The connector of item 48, wherein
the compressible element comprises a spring that is compressed by
movement of the first attachment area. [0257] Item 50. A connector
comprising a housing comprising: [0258] a first attachment area for
receiving and permanently attaching to an optical waveguide; [0259]
a second attachment area for receiving and permanently attaching to
an optical waveguide received and permanently attached at the first
attachment area; and [0260] a flexible carrier disposed within the
housing between the first and second attachment areas for
supporting and adhering to an optical waveguide received and
permanently attached at the first and second attachment areas, a
first end of the flexible carrier attached to the first attachment
area, a second end of the carrier attached to the second attachment
area.
[0261] Item 51. The connector of item 50, wherein the flexible
carrier is less flexible when initially bent and more flexible when
bent further. [0262] Item 52. The connector of any of claims 50
through 51, wherein the flexible carrier comprises: [0263] a
flexible first portion for supporting and adhering to an optical
waveguide received and permanently attached at the first and second
attachment areas; and [0264] a flexible second portion attached to
the flexible first portion at one or more discrete spaced apart
attachment locations. [0265] Item 53. The connector of item 52,
wherein the one or more discrete spaced apart attachment locations,
and the flexible first and second portions define at least one gap
therebetween. [0266] Item 54. The connector of any of items 52
through 53, wherein when bent along a length of the flexible
carrier, the flexible first portion is more flexible than the
flexible second portion. [0267] Item 55. The connector of any of
items 52 through 54, wherein when unbent, the flexible first
portion has a substantially planar lateral cross-sectional profile
and the flexible second portion has a substantially non-planar
lateral cross-sectional profile. [0268] Item 56. The connector of
any of items 52 through 55, wherein as the flexible carrier is bent
along a length of the flexible carrier, a lateral cross-sectional
profile of the flexible second portion changes from a substantially
non-planar profile to a substantially planar profile. [0269] Item
57. The connector of item 56, wherein the flexible second portion
is less flexible when having a substantially non-planar lateral
cross-sectional profile and more flexible when having a
substantially planar lateral cross-sectional profile. [0270] Item
58. The connector of item 52, wherein at least one attachment
location in the one or more discrete spaced apart attachment
locations extends along substantially an entire length of the
flexible carrier. [0271] Item 59. The connector of item 50, wherein
the flexible carrier comprises: [0272] a flexible first portion for
supporting and adhering to an optical waveguide received and
permanently attached at the first and second attachment areas; and
[0273] a flexible second portion attached to the top portion, such
that as the flexible carrier is bent along a length of the flexible
carrier, the flexible second portion collapses onto the flexible
first portion. [0274] Item 60. The connector of item 59, wherein
the flexible first portion has a first lateral cross-sectional
profile and the flexible second portion has a different second
lateral cross-sectional profile, wherein as the flexible second
portion collapses onto the flexible first portion, the lateral
cross-sectional profile of the flexible second portion changes from
the second lateral cross-sectional profile to the first lateral
cross-sectional profile. [0275] Item 61. The connector of any of
items 59 through 60, wherein the flexible second portion is
attached to the flexible first portion at an attachment location,
and wherein as the flexible second portion collapses onto the
flexible first portion, portions of the flexible second portion
rotate about the attachment location. [0276] Item 62. The connector
of item 61, wherein each of the flexible first and second portions
has a substantially planar cross-sectional profile when bent.
[0277] Item 63. The connector of item 59, wherein the flexible
second portion comprises a first flexible bottom portion attached
to the flexible first portion at a first attachment location, and a
second flexible second portion attached to the flexible first
portion at a different second attachment location, wherein as the
flexible second portion collapses onto the flexible first portion,
the first flexible second portion rotates about the first
attachment location, and the second flexible second portion rotates
about the second attachment location. [0278] Item 64. The connector
of item 63, wherein each of the flexible first portion, first
flexible second portion, and second flexible second portion has a
substantially planar cross-sectional profile when bent. [0279] Item
65. The connector of item 50, wherein the flexible carrier
comprises: [0280] a flexible first portion for supporting and
adhering to an optical waveguide received and permanently attached
at the first and second attachment areas; and [0281] a flexible
second portion, such that as the flexible carrier is bent along a
length of the flexible carrier, the flexible first and second
portions slide with respect to each other along the length of the
flexible carrier. [0282] Item 66. The connector of any of items 50
through 65, wherein when the connector is unmated and the optical
waveguide is received and permanently attached at the first and
second attachment areas, the optical waveguide is substantially
unbent between the first and second attachment areas. [0283] Item
67. The connector of any of items 50 through 66, further comprising
a light coupling unit disposed and configured to move within the
housing, the light coupling unit comprising: the second attachment
area for receiving and permanently attaching to the optical
waveguide received and permanently attached at the first attachment
area; and a light redirecting surface configured such that when the
optical waveguide is received and permanently attached at the first
and second attachment areas, the light redirecting surface receives
and redirects light from the optical waveguide, and the flexible
carrier and optical waveguide limit, but do not prevent, movement
of the light coupling unit within the housing. [0284] Item 68. The
connector of item 67, wherein as the connector mates with a mating
connector, the flexible carrier is configured to flex, to cause the
optical waveguide to bend, and to cause the light coupling unit to
rotate within the connector housing. [0285] Item 69. The connector
of item 67, wherein a mating of the light coupling unit with a
mating light coupling unit of a mating connector causes the
flexible carrier to flex and the optical waveguide to bend between
the first and second attachment areas, after the mating, the
flexible carrier and the optical waveguide applying spring force to
the light coupling unit and preventing the light coupling unit from
unmating from the mating light coupling unit. [0286] Item 70. The
connector of item 67, wherein after the connector mates with a
mating connector, mating surfaces of the light coupling unit and a
mating light coupling unit are disposed at an angle to a mating
direction of the connector. [0287] Item 71. The connector of item
67, wherein the first attachment area is configured to move within
the housing. [0288] Item 72. The connector of item 71, when the
optical waveguide is received and permanently attached at the first
and second attachment areas, a mating of the light coupling unit
with a mating light coupling unit of a mating connector is
configured to cause: [0289] the first attachment area to move
within the housing; [0290] the flexible carrier to flex; [0291] a
bend in the optical waveguide; and [0292] the light coupling unit
to move within the housing, wherein a spring force is applied by
the flexible carrier and the bend in the optical waveguide to the
light coupling unit, the spring force assisting in preventing the
light coupling unit from unmating from the mating light coupling
unit. [0293] Item 73. The connector of item 72, wherein during the
mating, the first attachment area moves in a direction
substantially perpendicular to a connector mating direction of the
connector. [0294] Item 74. The connector of item 72, wherein during
the mating, the first attachment area is configured to move in a
first direction and the light coupling unit is configured to move
in a second direction different from the first direction. [0295]
Item 75. The connector of item 72, wherein during the mating, the
light coupling unit rotates within the housing. [0296] Item 76. The
connector of any of items 50 through 75, further comprising a
registration feature, such that as the connector mates with a
mating connector along a mating direction, the registration feature
of the connector mates with a mating registration feature of the
mating connector, the mating registration feature causing the first
attachment area of the connector to move within the housing of the
connector. [0297] Item 77. The connector of item 76, wherein the
registration feature of the connector comprises an elongated
channel and the mating registration feature of the mating connector
comprises an elongated protrusion, such that as the connector mates
with the mating connector, the elongated protrusion slides within
the elongated channel, a front end of the elongated protrusion
sliding past the channel and making contact with the first
attachment area, the contact causing the first attachment area to
move within the housing of the connector. [0298] Item 78. The
connector of item 77, wherein during the mating, the mating
registration feature engages with a contact surface of the first
attachment area and applies a force to the contact surface causing
the first attachment area of the connector to move within the
housing of the connector. [0299] Item 79. The connector of item 78,
wherein the contact surface is a ramp. [0300] Item 80. The
connector of item 78, wherein the first attachment feature includes
a stop feature configured to limit movement of the mating
registration feature of the mating connector. [0301] Item 81. The
connector of any of claims 50 through 80, further comprising at
least one compressible element, wherein movement of the first
attachment area causes the compressible element to apply spring
force in a direction opposing a direction of movement of the first
attachment area. [0302] Item 82. The connector of item 81, wherein
the compressible element comprises a spring that is compressed by
movement of the first attachment area. [0303] Item 83. The
connector of any of items 50 through 82, wherein at least one of
the first and second flexible portions comprises a vibration
dissipating material. [0304] Item 84. The connector of any of items
50 through 83 wherein at least on of the first and second flexible
portions comprises a viscoelastic material for absorbing
energy.
[0305] Unless otherwise indicated, all numbers expressing feature
sizes, amounts, and physical properties used in the specification
and claims are to be understood as being modified in all instances
by the term "about." Accordingly, unless indicated to the contrary,
the numerical parameters set forth in the foregoing specification
and attached claims are approximations that can vary depending upon
the desired properties sought to be obtained by those skilled in
the art utilizing the teachings disclosed herein.
[0306] As used in this specification and the appended claims, the
singular forms "a," "an," and "the" encompass embodiments having
plural referents, unless the content clearly dictates otherwise. As
used in this specification and the appended claims, the term "or"
is generally employed in its sense including "and/or" unless the
content clearly dictates otherwise.
[0307] Spatially related terms, including but not limited to,
"lower," "upper," "beneath," "below," "above," and "on top," if
used herein, are utilized for ease of description to describe
spatial relationships of an element(s) to another. Such spatially
related terms encompass different orientations of the device in use
or operation in addition to the particular orientations depicted in
the figures and described herein. For example, if an object
depicted in the figures is turned over or flipped over, portions
previously described as below or beneath other elements would then
be above those other elements.
[0308] Unless otherwise indicated, the words "first," "second,"
"third," are used herein for identification of various features and
are not intended to imply any particular order, position, priority,
etc.
[0309] All references and publications cited herein are expressly
incorporated herein by reference in their entirety into this
disclosure, except to the extent they may directly contradict this
disclosure. Although specific embodiments have been illustrated and
described herein, it will be appreciated by those of ordinary skill
in the art that a variety of alternate and/or equivalent
implementations can be substituted for the specific embodiments
shown and described without departing from the scope of the present
disclosure. This application is intended to cover any adaptations
or variations of the specific embodiments discussed herein.
Therefore, it is intended that this disclosure be limited only by
the claims and the equivalents thereof.
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