Abstract
A field installable fiber optic connector is formed without the need to splice two opposing optical fibers together. A ferrule flange assembly with one or more crimp zones secures an optical fiber therein. The assembly is secured within a plug frame housing that has a bias spring, both secured therein by an extender cap. A cable retainer with at least two wings secures the optical cable when a retainer nut is screwed onto a backpost of the extender cap.
Claims
1. A ferrule flange assembly, comprising a ferrule flange body with a longitudinal bore; a ferrule with an optical fiber is secured to a first end of a ferrule flange body; a crimp zone positioned along the ferrule flange body; and wherein the crimp zone is collapsed about the optical fiber when a radial force is applied to the crimp zone.
2. The ferrule flange assembly of claim 1, wherein the optical fiber is inserted within a bore of the ferrule at a second end until the optical fiber is flush with a ferrule endface at a first end.
3. The ferrule flange assembly of claim 2, wherein the second end is configured to accept a protective tube about the optical fiber.
4. The ferrule flange assembly of claim 1, wherein a protective tube is positioned between the crimp zone and the optical fiber, the protective tube further protects the optical fiber when the radial force is applied to the crimp zone.
5. The ferrule flange assembly according to claim 1, wherein the optical fiber is a polymer optic fiber or a glass optical fiber.
6. A method of assembling a field terminated fiber optic connector, according to claim 1, further comprising the steps of: providing the ferrule secured within the ferrule flange assembly; inserting the optical fiber into ferrule flange assembly; and applying a radial force to the crimp zone along the ferrule flange body securing the optical fiber.
7. The method of assembling a field terminated fiber optic connector according to claim 6, further comprising the steps of: inserting the protective tube within the ferrule flange assembly and about the optical fiber; positioning a bias spring about the optical fiber between an extender cap and the ferrule flange assembly; inserting the ferrule flange assembly into a plug housing; securing the extender cap with the plug housing; placing a strength member about a threaded portion of the extender cap; receiving a cable retainer within a recess of the threaded portion of the extender cap; and securing a retainer nut with the threaded portion of the extender cap, thereby securing the fiber optic cable from movement.
8. The method of assembling a field terminated fiber optic connector according to claim 7, further comprising the steps of: securing the extender cap to the second end of the plug housing biases the spring forward to ensure the ferrule protrudes and aligns within the plug housing.
9. The method of assembling a field terminated fiber optic connector according to claim 7, further comprising the steps of: positioning the cable retainer onto the second end of the extender cap; securing the retainer nut about the threaded end secures a plural of wings of the cable retainer to hold the fiber optic cable thereby securing the optical cable from being pulled out of the plug housing.
10. A field installable fiber optic connector, comprising: a plug frame housing comprises a ferrule flange assembly with a crimp zone and a ferrule; and wherein the crimp zone is compressed about an optical fiber after the optical fiber is fully inserted into the ferrule thereby securing the optical fiber.
11. The field installable fiber optic connector according to claim 10, wherein a plug housing is configured to secure an extender cap.
12. The field installable fiber optic connector according to claim 11, wherein the optical cable further comprises a polymer optic fiber.
13. The field installable fiber optic connector to claim 12, wherein a spacer is positioned about the optical fiber when the optical fiber diameter is less than a bore size of the ferrule flange assembly.
14. A cable retainer, comprising: a main body; a first end further comprising one or more projections; a second end has at least two spaced apart tapered, frustoconical wings; the wings are separated by a slot; and wherein compressing the wings secures an optical cable within a longitudinal bore of the main body.
15. The cable retainer according to claim 14, wherein each wing has an inclined surface to guide the optical cable through the longitudinal bore.
16. The cable retainer according to claim 14, wherein the projection further comprises a chamfered leading edge.
17. The cable retainer according to claim 14, wherein the optical cable is a polymer optical fiber.
18. The cable retainer according to claim 14, further comprising the steps of: receiving the projection in a recess of an extender cap; and threading a retainer nut to a threaded backpost of the extender cap to compress the frustoconical wings about the optical cable thereby securing the optical cable within the main body.
19. The cable retainer according to claim 18, wherein the fiber optic cable is a polymer optical fiber.
20. The cable retained according to claim 14, where in a protective tube is positioned between the optical cable and the retainer nut.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1A is a ferrule flange assembly with crimp zones in the form of a rib;
[0019] FIG. 1B is perspective view of a second ferrule flange assembly;
[0020] FIG. 2A is a perspective view of a third ferrule flange assembly;
[0021] FIG. 2B is a perspective view of a fourth ferrule flange assembly with multiple crimp zones;
[0022] FIG. 3 is a perspective view of FIG. 1A with an optical fiber positioned with a bore of the ferrule flange assembly;
[0023] FIG. 4 is a perspective view of a field installed fiber optic connector;
[0024] FIG. 5 is an exploded view of FIG. 4 deploying one of the ferrule flange assembly embodiments;
[0025] FIG. 6 is a cross-section view of FIG. 4;
[0026] FIG. 7 is an exploded view of a second embodiment of a field installed connector;
[0027] FIG. 8 is a cross section view of the FIG. 7 connector assembled;
[0028] FIG. 9A is a perspective view of another embodiment of a field installed fiber optic connector;
[0029] FIG. 9B is an exploded view of FIG. 9A;
[0030] FIG. 9C is a cross-section view of FIG. 9A;
[0031] FIG. 10 is a zoomed view of the cable retainer section FIG. 6;
[0032] FIG. 11 is a perspective view of the cable retainer;
[0033] FIG. 12 is an exploded view of assembling the cable retainer to an extender cap;
[0034] FIG. 13 is an exploded view of applying the retainer nut to the extender cap;
[0035] FIG. 14 is perspective view of separating the components of FIG. 3 and FIG. 4.
[0036] FIGS. 15A-15G is a perspective view of assembling the connector of FIG. 4.
[0037] Corresponding reference numbers indicate corresponding parts throughout the figures.
DETAILED DESCRIPTION
[0038] The following terms shall have, for the purposes of this application, the respective meanings set forth below.
[0039] A connector is a device that completes a communication path from a fiber strand transmits a light signal to another connector or to transceiver electronics. The electronics convert the light signal into a digital signal. A connector is inserted and secured at either end of adapter, for example, a ferrule connector (FC), a fiber distributed data interface (FDDI) connector, an LC connector, a mechanical transfer (MT) connector, a standard connector (SC) connector, an SC duplex connector, or a straight tip (ST) connector. The connector may generally be defined by a connector housing body, an external latch or recess to secure said connector into adapter opening and one or more ferrules having optic fibers therein. In some embodiments, the housing body may incorporate any or all of the components described herein.
[0040] A receptacle is an adapter with internal structure to secure a proximal end or ferrule end of a connector within a port or opening. An adapter allows a first and second connector to interconnect or oppose each other to transmit a light signal from one part of a cable assembly to another, as an example. A receptacle may be a transceiver with an opening to receive a connector.
[0041] A fiber optic cable or an optical cable refers to a cable containing one or more optical fibers for conducting optical signals in beams of light. The optical fibers can be constructed from any suitable transparent material, including glass, fiberglass, polymer optical fiber, or plastic. The cable can include a jacket or sheathing material surrounding the optical fibers. Between the outer sheath and the optical fiber are strands of strength members or tensile members. In addition, the cable can be connected to a connector on one end or on both ends of the cable.
[0042] FIG. 1A depicts a first embodiment of ferrule flange assembly (10). Ferrule (40) positions an optical fiber (20) at a ferrule endface (40a). The optical fiber is fed through a bore (F-F) within the ferrule flange assembly until the optical fiber extends beyond the ferrule endface (40a). The installer will cleave and then polish the exposed optical fiber thereby forming the ferrule endface (40a) that is opposite another fiber optic connector endface to establish a communication path for light to be transmitted from a first optical fiber to a second optical fiber in the second fiber optic connector. Assembly (10) has main body (36) with one or more crimp zones (32) (as described in FIG. 3) formed as rib (10r) from a first end (FE) to a second end (SE) of the assembly (10). FIG. 1B depicts a second embodiment of the ferrule flange assembly (10a) with rib (10r) and/or flange (10f) as the crimp zone (32). FIG. 2A depicts a third embodiment of ferrule flange assembly (10c) with an extended ferrule (40), and rib (10r) near the first end (FE) and the second end (SE). FIG. 2B depicts one or more crimp zone (32) spaced apart along main body (36). Along main body (36) is one or more radial scoring (SC) as illustrated by the dotted lines. So when a radial force is applied between two radial score lines (SC), the intermediate portion will collapse about the optical fiber therein. The crimp zones may be grouped together closely or spaced apart, and of varying radial size.
[0043] FIG. 3 depicts the embodiment of ferrule flange assembly (10) of FIG. 1A. At the first end (FE) is a ferrule (40) that may be configured with an optical fiber (20a). The ferrule flange assembly further comprises flange (10f) as part main body (36). Alternatively, an optical fiber may be inserted from the second end (SE) and inserted within bore (F-F) (refer to FIG. 1A) until the optical fiber is positioned at ferrule endface (40a). Along the ferrule flange assembly (10) comprises one or more crimp zone (32) positioned along main body (36) in addition to flange (10f) configured as a crimp zone. As described above in FIGS. 1A, 1B and FIGS. 2A, 2B, the crimp zone may vary. In FIG. 3, the crimp zone (32) are spaced apart rib (10r) that are collapsed about the optical fiber within the bore of the assembly when radial force (RF) is applied about the circumferential outer surface of a rib. The optical fiber may be a polymer optical fiber, or a coated glass fiber and a protective tube (26) may be placed about the optical fiber to which the rib (10r) would be collapsed upon. The tube can act as a spacer when an optical fiber or assembly bore is mismatched due to manufacturing tolerances, while installing in the field. Also, the tube (26) may help prevent mirco-cracking of an optical glass fiber when it is compressed under the radial force imparted to a rib or crimp zone. A polymer optical fiber can withstand surface micro-cracks as a polymer fiber cross-section is relatively homogenous or of the same light transmitting medium.
[0044] FIG. 4 depicts an assembled field installable fiber optic connector (50) according to an embodiment of the present invention. Plug housing (12) secures the ferrule flange assembly (10) by capturing the flange (Of) within corresponding structure within the plug housing, such as a cut-out or recess configured to accept flange (10f). An extender cap (16) is secured to second end (SE) of the plug housing. Connection member (14) secures the connector within an adapter (not shown). The connection member is actuated by thumb release (11) that when depressed in direction of arrow D the connector (50) can be removed from an adapter port. Ferrule (40) protrudes from plug housing (12) when biased by spring (12d) (refer to FIG. 5). Retainer nut (1g) is threaded onto a threaded backpost of the extender cap forming connector (50). Optical cable (20) is secured to connector (50). The optical cable (20) further comprises optical fiber (20a), outer jacket (20b) and strength members (20s). Strength members (20s)(refer to FIG. 10) are strands of polyester or Kevlar.
[0045] FIG. 5 is an exploded view of FIG. 4. Assembly generally occurs in direction of arrow (A). Plug frame housing (12) accepts ferrule flange assembly (10), and optional protective tube (26) is placed about an optical fiber (not shown). The plug frame housing is also called a connector housing. Bias spring (12d) is positioned distal or nearer flange (10f) to biases the ferrule forward when connector (50) is mated opposite a second connector within an adapter (not shown). Extender cap (16) with thumb release latch (11) is secured to a second end of housing (12). Retainer cap (22) with two or more wings is positioned at a second end or distal end of a threaded backpost of the extender cap, as described below. Retainer nut (18) is threaded onto the backpost to form the connector (50).
[0046] FIG. 6 depicts a cross-section of assembled connector (50) of FIG. 4. Ferrule flange assembly (10) is secured within plug frame housing (12) with rib (10r) acting as crimp zone (32). There is more than one rib along main body (36) of ferrule flange assembly (10). Extender cap (16) has retainer nut (18) threaded (18c) with backpost threads (16p), and is further described in FIG. 10. Cable retainer (22) with frustoconical wing (20a.1, 20a.2, 20a.4) is compressed about optical cable (20) when retainer nut (18) is threaded onto backpost (16p) thereby improving pull strength of the fiber optic connector.
[0047] FIG. 7 depicts an exploded view of another embodiment of a field installed fiber optic connector (60). Connector (60) deploys the prior art crimp ring (12f) that is secured to a backpost of extender cap (16), with strain relief boot (12e) placed over the backpost. Ferrule flange assembly (10) is secured within plug frame housing (12) and the assembly is biased forward by spring (12d). Extender cap (16) is secured at the second end of plug frame housing (12). Dust cap (12g) is positioned over the ferrule when assembled. FIG. 8 is a cross-section view of connector (60) assembled. Ferrule flange assembly (10) is secured within housing (12), with one or more crimp zone (32). The prior art crimp tube (12f) is crimped over the backpost at two crimp points (12f.1, 12f.2) to secure optical cable (20) to establish a pull strength. Crimp zone (32) are compressed about optical fiber (20a) that is positioned within the bore (F-F) of the assembly (10), thereby securing optical fiber (20a) against being pulled out when the cable is pulled away from the connector at the second end. Without departing from the scope of the present invention, ferrule flange assembly (10) may be replaced by other ferrule flange assembly (10a, 10b or 10c) in connector (50, 60 or 70).
[0048] FIG. 9A is another embodiment of a field installable connector (70) assembled. FIG. 9B is an exploded view of connector (70). Connector (70), like connector (40) or connector (50), can deploy any one of the ferrule flange assembly (10, 10a, 10b or 10c) (refer to FIGS. 1A, 1B and FIGS. 2A, 2B). Connector (60) has a plurality of ferrule flange assembly (10) installed in the field as described above in FIG. 4. The group of ferrule flange assembly are housed in ferrule assembly subhousing (12c) that is secured within outer housing (12b). Subhousing (12c), ferrule flange assemblies (10), corresponding bias spring (12d) are secured together by rear housing (16e) along latch line (LL). Rear housing (16e) (refer to FIG. 9C) has a threaded backpost that can secure strength members (20s) between the threads of the backpost and inner threads of retainer nut (18). Backpost (16p) is threaded with a pair of wings (20a.1, 20a.2). A strain relief boot (12e) is attached to a second end of the rear housing (16e). FIG. 9C is a cross-section of the assembled connector (70). A plurality of ferrule flange assembly (10) are secured within subhousing (12c). Outer housing (12b) accepts backhousing (16e) and retainer nut (18) compresses wings (20a.1, 20a.2) about optical cable (20). Strength members (20s) are positioned between inner threads (18c) of retainer nut (18) and the backpost threads (16p). This increases optical cable pull strength. Wings (20a.1, 20a.2) are compressed about optical cable (20) when wings (20a.1) are compressed by retainer nut (18) when it is threaded onto the backpost. Back housing (16e) has a cavity that allows optical fibers to be positioned within and spaced apart without becoming entangled. Nearer a first end of the back housing, channels are formed to guide the optical fiber to the correct ferrule flange assembly (10).
[0049] FIG. 10 depicts extender cap (16) with threaded backpost (16p) having strength members (20s) laid on or about backpost threads. Cable retainer (22) is positioned onto backpost with projection (22a) aligned with a recess of the backpost. At least two frustoconical wing (20a.1, 20a.2) with slot (20s.4) therebetween is formed at second end of the retainer (22). The slots allow the wings to come together or close the slot gap during compressing by retainer nut (18). Retainer (22) has a bore through which optical cable (20) is fed or positioned therein. FIG. 11 depicts cable retainer (22) with main body (22c) and bore (22d) along longitudinal axis (L-L). At first end (FE) is at least one projection (22a, 22b) with chamfered edge or radius (22a.1, 22b.1). The chamfered edge helps guide the projection into receiver or recess (16b, 16c) located at a second end of the threaded backpost (16p). Each frustoconical wing (20a.1, 20a.2, 20a.4) has an inclined surface (20.2(1), 20a.3(1), 20a.4(1)). The inclined or tapered surface guides incoming optical cable (20) into the bore along (L-L) to help avoid jamming during a field installation of the cable with the connector. Referring to FIG. 12, at least one projection (22a, 22b) is received within corresponding recess (16b, 16c) to align and prevent rotation of cable retainer (22) when retainer nut (18) is being threaded onto backpost (16p). The wings (20a.1, 20a.2) are compressed about the optical cable helping to improve pull strength. Extender cap (16) latch (161.1) is received in a corresponding recess in a sidewall of the plug housing thereby securing extender cap (16) to a second end of the plug housing. FIG. 13 depicts optic cable (20) within cable retainer (22) and optical fiber (20a) extending through bore (16g) in extender cap (16) then through bore of ferrule flange assembly (10). Optical fiber (20a) will be inserted and secured by crimp zones as described above within ferrule flange assembly (10). Retainer nut (18) is screwed or twisted in direction of arrow (R) onto backpost (16p) where internal nut threads (18a) secure strength members (20s) therebetween. Assembly is in direction of arrow A.
[0050] FIG. 14 illustrates the field installable fiber optic connector components separated along optical fiber (20a). Optical fiber (20a) would be cleaved and polished once pushed through the bore of ferrule (40) to form ferrule end face (40a). In this embodiment strength members (20s) may be pushed through the ferrule flange assembly bore and when the crimp zone has a radial force (RF) applied, the members (20s) are secured with optical fiber (20a) within the bore of ferrule flange assembly (10). Optical cable (20) is through the bore of the extender cap (16). Cable retainer (22) is to be positioned on backpost (16p) that receives threaded retainer nut (18) as described above.
[0051] FIG. 15A to FIG. 15G depicts a method of field assembling a fiber optic connector deploying one of the ferrule flange assembly (10, 10a, 10b, or 10c). This assembly is similar between connectors (50, 60 or 70). FIG. 15A depicts optical fiber (20a) positioned through the bore of the extender cap (16) with bias spring (12d) positioned about cable (20). Cable retainer (22) is placed about optical cable (20) between extender cap (16) and retainer nut (18). FIG. 15B depicts the additional step adding optional protective tube (26), and then stripping back cable jacket (20b) (refer to FIG. 4) to expose one or more strength member (20s). FIG. 15C depicts securing ferrule flange assembly (10) by applying radial force (RF) about a crimp zone of ferrule flange assembly (10). This secures optical fiber (20a) within the bore of the ferrule flange assembly (10). The optical cable is pulled rearward placing ferrule flange assembly within plug housing (12). Plug housing is secured to the extender cap forming an intermediate connector assembly as depicted in FIG. 15D. Strength member (20s) is positioned about threaded backpost (16p). In FIG. 15E, retainer nut (18) is threaded onto backpost (16p) as shown in FIG. 13 in direction of arrow (R). FIG. 15F depicts fiber (20a) is cleaved and is polished to form a ferrule end face (40a). FIG. 15G depicts installing a dust cap (12g).
[0052] In the above detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims am not meant to be limiting.
[0053] With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application.
[0054] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (for example, bodies of the appended claims) are generally intended as open terms (for example, the term including should be interpreted as including but not limited to, the term having should be interpreted as having at least, the term includes should be interpreted as includes but is not limited to, et cetera).
