Fixture and method for polishing fiber optic connector ferrules

Abstract

A holder to polish a fiber optic connector having at least two ferrule assembly. Each ferrule assembly having a ferrule with an optical fiber therein. And a tool to rotate a ferrule assembly within the connector housing to allow opposing ferrules, with an APC surface, to transfer a light signal with minimal surface reflection, or data loss.

Claims

1. A method of making an angle polish cut (APC) optical fiber connector comprising: providing a unitary connector housing defining an interior containing a first ferrule and a second ferrule, each ferrule having a flange and an angle polished cut and being located in an original rotational position, the unitary connector housing comprising a perimeter wall extending 360° about the interior and a contiguous ferrule flange wall extending across the interior, first and second ferrule springs biasing the first and second ferrules forward in the interior of the unitary housing such that the flanges of the first and second ferrules engage the contiguous ferrule flange wall, the unitary connector housing having a contiguous two-ferrule opening through a front end of the unitary connector housing, each of the first ferrule and the second ferrule extending through the contiguous two-ferrule opening such that the first and second ferrules protrude forwardly from the front end of the unitary connector housing; reaching into the interior of the unitary connector housing through the contiguous two-ferrule opening with a tool to engage the first ferrule; rotating the first ferrule gripped by the tool in the unitary connector housing about a longitudinal axis of the first ferrule while the second ferrule remains in the original rotational position; wherein reaching into the interior of the unitary connector housing comprises meshing the tool with structure on a flange of the first ferrule so that the tool and ferrule are engaged for conjoint rotation; wherein meshing the tool with structure on the flange of the first ferrule comprises inserting a protrusion on the tool into a slot on the flange of the first ferrule.

2. The method of claim 1 wherein rotating the first ferrule comprises rotating the first ferrule through an angle of 45° from the original rotational position of the first ferrule.

3. The method of claim 1 wherein rotating the first ferrule comprises rotating the first ferrule about 90° from the original position.

4. The method of claim 1 wherein meshing the tool with structure on the flange of the ferrule occurs within the unitary connector housing.

5. The method of claim 1 wherein providing the unitary connector housing includes providing a cavity forming the interior of the unitary connector housing, the cavity receiving both of the first and second ferrules.

6. The method of claim 1 wherein providing the unitary connector housing includes polishing the first and second ferrules at the same time while held in the unitary connector housing to form the angle polished cut on the first and second ferrules.

7. The method of claim 1, wherein the contiguous two-ferrule opening comprises a first portion receiving the first ferrule and a second portion receiving the second ferrule.

8. The method of claim 7, wherein reaching into the interior of the unitary connector housing comprises positioning a portion of the tool in the first portion of the contiguous two-ferrule opening and keeping the second portion of the contiguous two-ferrule opening open.

9. The method of claim 1, wherein the contiguous ferrule flange wall comprises a first ferrule hole receiving the first ferrule and a second ferrule hole receiving the second ferrule, the first and second ferrule holes being non-contiguous.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiments of the invention are described in more detail hereinafter with reference to the drawings, in which:

(2) FIG. 1 depicts a prior art duplex ferrule connector.

(3) FIG. 2 is an exploded view of FIG. 1.

(4) FIG. 2A is a perspective view of an alternative duplex ferrule connector.

(5) FIG. 3 is a perspective view of a ferrule assembly according to the present invention.

(6) FIG. 4 is a front or proximal view of FIG. 1 connector with FIG. 3 ferrule assembly.

(7) FIG. 5A is a holder or jog for the connector of FIG. 1.

(8) FIG. 5B is the connector of FIG. 1 secured in the holder of FIG. 5A.

(9) FIG. 5C1 is a top view of FIG. 5A holder.

(10) FIG. 5C2 is a side view of FIG. 5A holder.

(11) FIG. 5C3 is a front view of FIG. 5A holder.

(12) FIG. 5C4 is a view of a hook to secure connector of FIG. 1 within holder of FIG. 5C1.

(13) FIG. 6 is a prior art polishing jig for a single ferrule connector.

(14) FIG. 7A is the connector of FIG. 1 with its ferrule end faces polished to APC or 8 degree angle.

(15) FIG. 7B is the connector of FIG. 1 after APC polishing.

(16) FIG. 7C is the full insertion of the FIG. 1 connector within holder of FIG. 5A.

(17) FIG. 7D is the connector of FIG. 1 after APC polishing,

(18) FIG. 7E is a side view and top view of ferrules after APC polishing.

(19) FIG. 8A is a tool to orient the ferrule assembly of FIG. 3 after the ferrule is APC polished.

(20) FIG. 8B is an exploded view of a second end of FIG. 8A tool.

(21) FIG. 9 is a table of reflection losses by end face polish type depicting reflection loss.

(22) FIG. 10A is FIG. 8A tool secured to ferrule assembly to rotate ferrule after APC polish.

(23) FIG. 10B is rotation step of FIG. 1A.

(24) FIG. 10C depicts removing the tool of FIG. 8A off the ferrule.

(25) FIG. 10D depicts rotating the second ferrule.

(26) FIG. 11A depicts proper orientation of the APC polished ferrules.

(27) FIG. 11B is a side, front perspective view of the ferrules of FIG. 11A.

(28) FIG. 11C depicts bottom view of ferrules after APC polish and orientation.

(29) FIG. 12 depicts abutting two APC ferrule end faces to achieve minimal reflection loss.

DETAILED DESCRIPTION

(30) In the following description, apparatuses for mating two multi-fiber optic ferrules. The ferrules end face being formed of an APC cut, as shown in FIG. 12. It will be apparent to those skilled in the art that modifications, including additions and/or substitutions may be made without departing from the scope and spirit of the invention. Specific details may be omitted so as not to obscure the invention; however, the disclosure is written to enable one skilled in the art to practice the teachings herein without undue experimentation.

(31) FIG. 1 depicts a prior art connector 100 having a plural of ferrule assembly (10a, 10b). FIG. 2 is an exploded view of connector 100 depicting bias springs 3, ferrule assembly (10a, 10b), connector housing 2, recess 12, and a dust cap 1. FIG. 2A is an alternative duplex ferrule connector 200 with a connector housing 201, alignment tab 205 and recess 212. As with connector 100, connector 200 recess is secured by a latch with holder 500. Connector 200 has an alignment tab 205 which aids in placement of connector 200 within holder 500.

(32) FIG. 3 depicts a ferrule assembly with a ferrule having an optical fiber therein, and a flange with a pair of opposing slot cut outs (11a.1, 11a.2). FIG. 4 depicts an end view or proximal view of connector 100 showing the ferrule assembly 10a, 10b and slot cutouts 11a.1, 11a.2 and 11b.1, 11b.2 respectively. The slot cut outs accept a corresponding protrusion at a second end of a tool as shown in FIG. 8A.

(33) FIG. 5A is a holder or jig that accepts connector 100 in a configuration capable of applying an APC polish to both ferrule end faces at the same time. An APC polish places an 8 degree angle on a flat-end face ferrule. Prior art polishing is one ferrule at a time. The jig holds the connector at an 8 degree angle. The jig is secured to the face of a polishing surface, using a pair of tabs at the base of the holder. FIG. 5B depicts connector 100 in holder 500. FIG. 5C1 is a top view of holder 500. FIG. 5C2 is a side view of holder 500. FIG. 5C3 is a front view of holder 500.

(34) FIG. 5C4 depicts a hook comprising a body, holder 500 locking surfaces 114, and flexible arms 112. The arms 112 flex upward and are received in a recess 12 of connector upon insertion of connector 100 into holder 500. locking surfaces 114 aid in securing hook 110 within cut-outs (not shown) within holder.

(35) FIG. 6 is a prior art polishing jig 600 with a plural of holders 624 for securing a connector 620 with a single ferrule. By contrast, the present invention is a jig that can hold ABC polish two or more ferrules. The jig can be attached to the polisher surface 622 similar to holder 624.

(36) FIG. 7A depicts connector 100 without an APC polish at the ferrule 10a. FIG. 7B depicts connector 100 with an APC polish applied to ferrule 10a′. FIG. 7C depicts connector 100 within jig 500 prior to applying an APC polish. FIG. 7D is a connector 100 after an ABC polish is applied to ferrule 10a′. FIG. 7E depicts side view and top view of polish applied to ferrule tip 10a′.

(37) FIG. 8A is an orienting tool 800 that rotates an APC polished ferrule 10a′, at the proximal end of connector 100. A first end comprises a handle 812 and a second end comprises a tip with a pair of protrusions (816a, 816b), connected by shaft 814. FIG. 8B is an exploded view of tip showing the protrusions.

(38) FIG. 9 depicts various ferrule end face cuts, and a table of estimated reflection loss in decibels when two ferrules with the same end cut are opposing each other in an adapter. A more negative decibel means less power loss.

(39) FIG. 10A depicts tool 800 inserted in the direction “I” and secured to ferrule assembly 10a. The tool protrusions (816a, 816b) engage slot cuts (11a.1, 11a.2) at the proximal end “P”, and user pushes the ferrule assembly in a distal direction and rotates (“R”) the ferrule assembly 10a′, by 90 degrees, in FIG. 10B. In FIG. 10C, the tool 800 is withdrawn proximally, and spring 3a biases ferrule assembly forward (“RM”) in connector housing 2. FIG. 10D depicts using tool 800 to rotate the second ferrule assembly (10b′) 90 degrees, After both ferrule assembly (10a′, 10b′) are rotated 90 degrees, the APC cut ferrule end faces are in a proper orientation as shown by FIG. 11A. FIG. 11B depicts side view of polished ferrules to an APC angle of 8 degrees of FIG. 11A. FIG. 11C depicts bottom view of APC ferrules after orientation using tool 800. FIG. 12 depicts abutting or inserting of a two connectors 100 after APC polish in an adapter (not shown). FIG. 12 shows how the APC polished end faces will abut with no air gap to reduce reflection loss, as estimated in FIG. 9.

(40) An ordinarily skilled person in the art can appreciate that by following the principal of the present invention, a version of the adapter for mating a multi-fiber optic ferrule with another multi-fiber optic ferrule can be derived without departing from the scope and spirit of the invention. Although the embodiments of the present invention described herein are related to multi-fiber optic applications, the present invention can be adapted to single fiber optic applications. Specific details may be omitted so as not to obscure the invention; however, the disclosure is written to enable one skilled in the art to practice the teachings herein without undue experimentation.

(41) The foregoing description of the present invention has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations will be apparent to the practitioner skilled in the art.

(42) The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, thereby enabling others skilled in the art to understand the invention for various embodiments and with various modifications that are suited to the particular use contemplated.