A fiber optic alignment device includes a first and a second alignment block and a first and a second gel block. A fiber passage extends from a first end to a second end of the fiber optic alignment device. The fiber passage is adapted to receive a first optical fiber through the first end and a second optical fiber through the second end. An intermediate portion of the fiber passage is positioned between the first and the second ends. The intermediate portion is adapted to align the first and the second optical fibers between the first and the second alignment blocks. A first portion of the fiber passage is positioned between the first end and the intermediate portion of the fiber passage. The first portion extends between the first alignment block and the first gel block. A second portion of the fiber passage is positioned between the second end and the intermediate portion of the fiber passage. The second portion extends between the second alignment block and the second gel block. End portions of the first and the second optical fibers may be cleaned when slid between the alignment blocks and the gel blocks. The fiber passage may include an undulating portion.

A process and tool for reshaping and resizing grooves that were pre-formed in a pair of ferrules halves of an optical fiber ferrule. A high-precision alignment fixture produces a ferrule assembly with an optical fiber precisely held therein in alignment with the external alignment surface of the ferrule assembly. The fixture uses a double-compound flexure supporting a linearly moving body (e.g., a reshaping and resizing jaw), which eliminates parasitic displacement in a direction lateral to the direction of linear motion of the moving body. Each compound flexure includes a pair of double parallel leaf springs (in series).

An expanded beam ferrule includes a first ferrule halve having reflective surfaces and a second ferrule halve, which together retain optical fibers. The reflective surfaces output light perpendicular to the mid-plane of the ferrule. A sleeve aligns the external surface of two similar ferrules, with the reflective surfaces of the respective ferrules facing each other. Output light from an optical fiber held in the first ferrule is bent and collimated by a reflective surface, transmitted to the facing reflective surface in a second ferrule aligned by the sleeve, which bends the light to input to the optical fiber held in the second ferrule. The ferrule components and/or sleeve are precision formed by high throughput metal stamping. The ferrule is incorporated in an optical fiber connector.

A process and tool for reshaping and resizing grooves that were pre-formed in a pair of ferrules halves of an optical fiber ferrule. The pre-formed grooves are further subject to a separate, subsequent reshaping and resizing step using the tool and a gauge that may be a bare section of optical fiber or a pin. The ferrule halves are aligned, and using the pre-formed grooves as guides for the gauge optical fiber or gauge pin, the ferrule halves are compressed together with the gauge optical fiber or gauge pin therebetween, thereby reshaping and resizing the respective grooves on the ferrule halves. After reshaping and resizing, the resultant groove that is finally formed on each ferrule halve would be precisely shaped, sized and located with respect to the external alignment surface of each ferrule halve. The ferrule halves may be used to terminate an optical fiber cable.

A fiber optic alignment device includes a first and a second alignment block and a first and a second gel block. A fiber passage extends from a first end to a second end of the fiber optic alignment device. The fiber passage is adapted to receive a first optical fiber through the first end and a second optical fiber through the second end. An intermediate portion of the fiber passage is positioned between the first and the second ends. The intermediate portion is adapted to align the first and the second optical fibers between the first and the second alignment blocks. A first portion of the fiber passage is positioned between the first end and the intermediate portion of the fiber passage. The first portion extends between the first alignment block and the first gel block. A second portion of the fiber passage is positioned between the second end and the intermediate portion of the fiber passage. The second portion extends between the second alignment block and the second gel block. End portions of the first and the second optical fibers may be cleaned when slid between the alignment blocks and the gel blocks. The fiber passage may include an undulating portion.

A ferrule for a high density optical fiber connector, supporting a first set of optical fibers of a first fiber cable and a second set of optical fibers of a second fiber cable. The ferrule supports the first and second sets of optical fibers in at least one plane. In one embodiment, the first set of optical fibers are supported in a first row of open grooves, and the second set of optical fibers are supported in a second row of open grooves. The optical fibers in the first row are staggered with respect to the optical fibers of the second row. The ferrule comprises two halves, each having an open structure that has a row of open grooves precisely formed thereon in a plane. In another embodiment, the ferrule supports the first and second sets of optical fibers in a single row, in an alternating interleaving manner.

A fiber optic alignment device includes a first and a second alignment block and a first and a second gel block. A fiber passage extends from a first end to a second end of the fiber optic alignment device. The fiber passage is adapted to receive a first optical fiber through the first end and a second optical fiber through the second end. An intermediate portion of the fiber passage is positioned between the first and the second ends. The intermediate portion is adapted to align the first and the second optical fibers between the first and the second alignment blocks. A first portion of the fiber passage is positioned between the first end and the intermediate portion of the fiber passage. The first portion extends between the first alignment block and the first gel block. A second portion of the fiber passage is positioned between the second end and the intermediate portion of the fiber passage. The second portion extends between the second alignment block and the second gel block. End portions of the first and the second optical fibers may be cleaned when slid between the alignment blocks and the gel blocks. The fiber passage may include an undulating portion.

An optical fiber bundle connector includes a plurality of optical fibers, a plastic tube, a ferrule, an intermediate member, a frame member, and a pressing member. A portion of each of the plurality of optical fibers is inserted in the plastic tube. The ferrule extends in a first direction and holds tip portions of the plurality of optical fibers. The intermediate member has a cylindrical shape. The plurality of optical fibers are inserted in the intermediate member. The intermediate member connects the plastic tube and the ferrule. The frame member accommodates at least a portion of the ferrule, the intermediate member, and at least a portion of the plastic tube. The pressing member is disposed around the intermediate member and configured to press the ferrule toward a tip side of each of the plurality of optical fibers against the frame member.