Field terminated ruggedized fiber optic connector system

Abstract

Ruggedized field terminated optical fiber connector systems comprising a field terminated connector assembly including a drop cable coupled to a connector, the drop cable having a custom length. The ruggedized field terminated connector system may further comprise a rugged front portion configured to slide over at least a portion of the field terminated connector assembly, and a rear connector body configured to couple to the rugged front portion. The rear body has a crimp ring and a grommet is slide into said crimp ring, and secured therein.

Claims

1. A ruggedized field terminated optical fiber connector system comprising: a field terminated connector assembly including a drop cable coupled to a connector, the drop cable having a custom length; a ruggedized front portion configured to slide over at least a portion of the field terminated connector assembly; and a rear connector body configured to slide forward along the drop cable to couple to the ruggedized front portion; a crimp ring; a grommet; wherein the crimp ring is configured to be crimped onto the grommet; wherein before the crimp ring is crimped onto the grommet, the crimp ring is integrally connected to the rear connector body such that the crimp ring is configured to move conjointly with the rear connector body as the rear connector body slides forward along the drop cable to couple to the ruggedized front portion; and wherein before the crimp ring is crimped onto the grommet, the grommet is movable with respect to the crimp ring and the rear connector body and is configured to be pushed into said crimp ring.

2. The ruggedized field terminated optical fiber connector system of claim 1, wherein the crimp ring includes a crimp tool alignment mark.

3. The ruggedized field terminated optical fiber connector system of claim 1, further comprising a coupling nut having a front end and a rear end, the ruggedized front portion protruding from the front end and the rear connector body protruding from the rear end.

4. The ruggedized field terminated optical fiber connector system of claim 3, further comprising a strain relief member configured to couple to the coupling nut.

5. The ruggedized field terminated optical fiber connector system of claim 4, wherein the strain relief member is configured to snap on the coupling nut.

6. The ruggedized field terminated optical fiber connector system of claim 1, wherein the rear connector body is configured to snap onto the ruggedized front portion.

7. The ruggedized field terminated optical fiber connector system of claim 1, wherein the ruggedized front portion includes at least one sealing member.

8. The ruggedized field terminated optical fiber connector system of claim 1, wherein the crimp ring has an interior and the crimp ring is sized and arranged for receiving at least a portion of the grommet in the interior.

9. The ruggedized field terminated optical fiber connector system of claim 1, wherein the rear connector body is over-molded onto the crimp ring.

10. A ruggedized field terminated optical fiber connector system comprising: a field terminated connector assembly having a drop cable coupled to a connector, the drop cable having a custom length; a connector body configured to be disposed over at least a portion of the field terminated connector assembly; a crimp ring; and a grommet; wherein the crimp ring is configured to be crimped onto the grommet; wherein before the crimp ring is crimped onto the grommet, the crimp ring is integrally connected to a rear portion of the connector body such that the crimp ring and the rear portion of the connector body move together with respect to the field terminated connector assembly as a single part; and wherein before the crimp ring is crimped onto the grommet, the grommet is movable with respect to the crimp ring and the rear connector body and is configured to be pushed into said crimp ring.

11. The ruggedized field terminated optical fiber connector system of claim 10, wherein the crimp ring includes a crimp tool alignment mark.

12. The ruggedized field terminated optical fiber connector system of claim 10, wherein the crimp ring has an interior and the crimp ring is sized and arranged for receiving at least a portion of the grommet in the interior.

13. The ruggedized field terminated optical fiber connector system of claim 10, wherein the rear portion of the connector body is over-molded onto the crimp ring.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of a prior art field terminated optical fiber connector system, showing a drop cable terminated by a field installable connector;

(2) FIG. 2 is an expanded view of the field terminated optical fiber connector system of FIG. 1;

(3) FIGS. 3A to 3D illustrate the field termination steps of the field terminated optical fiber connector system of FIG. 1;

(4) FIGS. 4A to 4I illustrate the field termination steps of one embodiment of a ruggedized field terminated optical fiber connector system according to aspects of the present disclosure;

(5) FIG. 4J is a perspective view of the ruggedized field terminated optical fiber connector system assembled as shown in FIGS. 4A to 4I according to aspects of the present disclosure;

(6) FIGS. 5A to 5G illustrate the field termination steps of another embodiment of a ruggedized field terminated optical fiber connector system according to aspects of the present disclosure; and

(7) FIG. 5H is a perspective view of the ruggedized field terminated optical fiber connector system assembled as shown in FIGS. 5A to 5G according to aspects of the present disclosure.

DETAILED DESCRIPTION

(8) As used herein, the term optical fiber is intended to apply to all types of single mode and multi-mode light waveguides, including one or more bare optical fibers, coated optical fibers, loose-tube optical fibers, tight-buffered optical fibers, ribbonized optical fibers, bend performance optical fibers, bend insensitive optical fibers, nanostructured optical fibers or any other expedient for transmitting light signals. The term optical fiber cable may further include multi-fiber optic cables having a plurality of the optical fibers.

(9) For connection of cables together or with other fiber optic devices, the terminal ends of a cable may include a connector. A connector may include a housing structure configured to interact with and connect with an adapter. An adapter, in a simple form, may include two aligned ports for aligning fiber optic connectors and/or electrical connectors therein to align and connect optical fibers end-to-end, or allow for pin/socket electrical connections.

(10) Various embodiments provide field terminated weatherproof optical drop cable and connector systems using non-ruggedized field installable optical connectors. Various embodiments provide a field terminating system used in the making of optical fiber cables, such as drop cables, to be deployed for outside plant (uncontrolled environment) conditions.

(11) Prior weatherproof ruggedized optical connection cables are factory made, only in common lengths, and delivered into the field where they are used to extend optical fiber service from a centralized distribution enclosure to a nearby customer. The cable length chosen to connect these two points may be significantly longer than needed.

(12) Various embodiments address the problem of installing outdoor optical drop cables made in lengths that are always longer than necessary to reach between a centralized distribution point (Fiber Distribution Hub or FDH) and the subscriber's optical network terminal (ONT). Optical network companies and/or hired installation sub-contractors stock selective standard optical drop cable lengths in order to provide optical network service to a new subscriber. The chosen cable length from stock needs to be equal to or greater than the minimum calculated distance between FDH and ONT. It is almost always a length that is greater than the measured distance.

(13) Having excess cable length results in extra work for the installer because the installer needs to coil up and store the excess either near the FDH (e.g. on a utility pole) or at the ONT, in some cases at the exterior wall of a building (commercial or residential). Further, even if the drop cable construction is sufficiently flexible to coil up for storage, the minimum bending radius of the cable may be several inches. The result of several coiled up drop cables located close to the FDH can become unsightly. A further disadvantage is the cost of stored drop cable inventories and extra cost of the cable itself when comparing the length from stock and the actual cable length needed for the same job.

(14) Various embodiments disclosed herein allow drop cables to be of custom lengths to suit every drop cable run perfectly. Thus, various embodiments may be used in the field to build the perfect cable length (no excess) to span the distance between the FDH and the ONT.

(15) Advantages of embodiments disclosed herein include reducing installer effort, and the costs associated with the excess cable length and inventories. Another advantage is to greatly improve the looks of the installation because looped excess cable is eliminated.

(16) Furthermore, various embodiments improve drop cable repairs. If a drop cable becomes irreparably damaged, the general approach is to replace the entire drop cable. Embodiments disclosed herein may be used to simply replace the failed connector of an existing drop cable. The bad connector is simply cut off, a minimal length of the excess cable is then expertly prepared (for example, stripped, cleaned and cleaved), and the field installable ruggedized connector assembly is added. This is all done at a fraction of the cost for an entire drop cable replacement, including the cost of performing aerial or underground construction.

(17) FIG. 1 shows a prior art field terminated optical fiber connector system 100, including a drop cable 102 terminated by a field installable connector assembly 104. The drop cable 102 is a 2 mm3 mm rectangle type outdoor rated optical fiber drop cable. However, in various embodiments disclosed herein, other types of drop cables may be used. The connector assembly 104 includes an SC type field installable optical fiber connector. However, in various embodiments disclosed herein, other types of optical fiber connectors may be used.

(18) FIG. 2 shows an expanded, disassembled view of the field terminated optical fiber connector system 100. FIG. 2 further shows a cable end adapter 106. The cable end adapter 106 has an internal passage 108 having a size and shape configured to match the size and shape of the drop cable being used, in this case the drop cable 102. Various embodiments of ruggedized optical fiber connector systems configured according to aspects of the present disclosure may include the field terminated optical fiber connector system 100, or other types of optical fiber connector systems.

(19) FIGS. 3A to 3D illustrate the field termination steps of the field terminated optical fiber connector system 100. FIG. 3A shows the drop cable 102 coupled to the cable end adapter 106. The cable 102 may then be inserted, in the direction of the arrow 110, into the optical fiber connector assembly 104, as shown in FIG. 3B. Fiber clamping may be performed, for example, per connector installation instructions. The optical fiber connector assembly 104 includes a cover 112 that is closed, as shown for example in FIG. 3C, after the cable end adapter 106 and the cable 102 are received by the connector assembly 104.

(20) The connector assembly 104 further includes an outer body 114 and a connector 116. As shown in FIG. 3D, the outer body 114 is removed from the connector assembly 114, revealing the connector 116. The connector 116 is an SC type field installable connector, as described above. Other embodiments may use other types of connectors. The outer body 114 may be discarded after removing it from the connector assembly 104. Thus, the outer body 114 is removable and the field terminated optical fiber connector system 100 need not include the outer body 114. In various embodiments disclosed herein, the drop cable is field terminated and may thus have a custom length.

(21) FIGS. 4A to 4I illustrate the field termination steps of one embodiment of a ruggedized field terminated optical fiber connector system 200 shown in FIG. 4J. The ruggedized field terminated optical fiber connector system 200 includes the field terminated optical fiber connector system 100 of FIG. 3D, including the connector 116. In other embodiments, other types of connectors, connector assemblies and drop cables may be used.

(22) The ruggedized field terminated optical fiber connector system 200 includes a rugged front portion 202 configured to slide over at least a portion of the field terminated connector system 100, in a rearward direction shown by the arrow 204 in FIG. 4A. FIG. 4B shows a portion of the ruggedized field terminated optical fiber connector system 200, including the rugged front portion 202 covering at least a portion of the connector assembly 114. The rugged front portion 202 includes at least one sealing membrane, such as the O-ring 206.

(23) FIG. 4C shows a portion of the ruggedized field terminated connector system 200, further comprising a slide on coupling nut 208, a slide on sealing washer 210, and a slide on rear connector body 212. The rear connector body 212 includes at least one crimp ring 214. In this embodiment, the rear connector body 212 is made of plastic, with an over-molded soft brass crimp ring 214. In other embodiments, other materials may be used.

(24) The coupling nut 208 is configured to slide over the rugged front portion 202. The sealing washer 210 is configured to slide into the coupling nut 208. The rear connector body 212 is configured to couple to the rugged front portion 202. In this example, the rugged front portion 202 and the rear connector body 212 are configured to couple by at least one snap fit. The rugged front portion 202 includes a protrusion 218, whereas the rear connector body 212 includes an opening 216 configured to receive the protrusion so as to couple the rugged front portion to the rear connector body. In other embodiments, the rear connector body 212 may include the protrusion and the rugged front portion 202 may have a corresponding opening.

(25) FIG. 4D is a perspective view of part of the ruggedized field terminated connector system 200, showing the rugged front portion 202 coupled to the rear connector body 212, and a coupling nut 208 coupled to both the rugged front portion 202 and the rear connector body 212. Sealing members such as the O-ring 206 and the sealing washer 210 further weatherproof the connector system.

(26) FIG. 4E shows the ruggedized connector system 200 further comprises a grommet 220. The grommet 220 may be made of rubber or another material. The grommet is pushed towards the front of the connector system in the direction of the arrow 222, and into the crimp ring 214. In some embodiments, the entire length of the grommet 220 may not fit inside the crimp ring 214. Thus, a portion 226 of the grommet 220 may protrude from the crimp ring 214, as shown for example in FIG. 4F.

(27) In some embodiments, the crimp ring 214 comprises a crimp tool alignment mark 224. As shown in FIG. 4G, a crimp tool 230 may be used to crush the crimp ring 214 onto the rubber grommet 220.

(28) As shown in FIG. 4H, the ruggedized field terminated optical fiber connector system 200 further comprises a wave washer 240 and a strain relief member 242. The wave washer 240 is configured to slide up against the crimp ring 214, as shown in FIG. 4I. The strain relief member 242 is configured to snap to the coupling nut 208. The coupling nut 208 includes at least one tab 244, and the strain relief member 242 includes at least one opening 246 configured to receive a respective tab 244 so as to couple the strain relief member with the coupling nut. In this example, two tabs 244 and two openings 246 are disposed at opposite sides of the strain relief member 242 and the coupling nut 208 to form two snap latches.

(29) FIG. 4J is a perspective view of the ruggedized field terminated optical fiber connector system 200 assembled as shown in FIGS. 4A to 4I according to aspects of the present disclosure. The strain relief member 242 is latched on to the coupling nut 208 using the snap latches. Other embodiments may be configured with more or less components than described and illustrated with reference to FIGS. 4A to 4I.

(30) FIGS. 5A to 5G illustrate the field termination steps of another embodiment of a ruggedized field terminated optical fiber connector system 300 according to aspects of the present disclosure. FIG. 5A shows a part of the ruggedized field terminated connector system 300, comprising the field terminated connector system 100, and further comprising a connector body 302 configured to slide in a longitudinal direction along the arrow 304. The connector body 302 includes a connector body tip 306. The ruggedized field terminated connector system 300 further comprises a connector tip clip 308.

(31) The connector tip clip 308 is configured to couple to the connector body tip 306 as shown in FIG. 5B. The connector tip clip 308 and the connector body tip 306 are configured to snap latch. For example, the connector tip clip 308 includes at least one tab 310 configured to snap into a corresponding opening 312 of the connector body tip 306. In other embodiments, the connector body tip 306 may include a tab and the connector tip clip 308 may include a corresponding opening. In various embodiments, any number of snap latches may be provided to couple the connector tip clip 308 to the connector body tip 306. For example, as shown in FIG. 5C, the connector tip clip 308 is snapped into the connector body tip 306 at two opposite sides of the connector system 300. In this embodiment, the snap is disposed on the connector body tip 306 which is at a front end of the connector body 302. In other embodiments, the snap may be disposed on another portion of the connector body 302.

(32) FIG. 5C further shows the connector body 302 having a crimp ring 318 and a crimp tool alignment mark 320. The crimp ring 318 and the crimp tool alignment mark 320 are disposed at a rear end of the connector body 302, and the connector body tip 306 is disposed at a front end of the connector body.

(33) FIG. 5D shows the ruggedized connector system 300 further comprises a grommet 322. The grommet 322 may be made of rubber or another material. The grommet 322 is pushed towards the front of the connector system 300 in the direction of the arrow 324, and into the connector body 302, and specifically into the crimp ring 318. In some embodiments, the entire length of the grommet 322 may not fit inside the connector body 302. Thus, a portion 328 of the grommet 322 may protrude from the rear end of the crimp ring 318, as shown for example in FIG. 5E.

(34) In some embodiments, as described above, the connector body 302 comprises a crimp tool alignment mark 320. Once the grommet 322 is inserted into the crimp ring 318, a crimp tool 330 may be used to crush the crimp ring 318 onto the rubber grommet 322 at the location of the crimp tool alignment mark 320, as shown in FIG. 5F.

(35) As shown in FIG. 5G, the ruggedized field terminated optical fiber connector system 300 further comprises a connector coupling 340 having a strain relief member 342. The connector coupling 340 is configured to slide onto the connector body 302.

(36) FIG. 5H is a perspective view of the ruggedized field terminated optical fiber connector system 300 assembled as shown in FIGS. 5A to 5G according to aspects of the present disclosure. The connector coupling 340 is coupled to the connector body 302 such that the connector body tip 306 protrudes from the front portion of the connector coupling. The strain relief member 342 is positioned at the rear portion of the connector coupling 340. The ruggedized field terminated optical fiber connector system 300 is compatible with Opti-tap connectors by Corning.

(37) Various parts, components or configurations described with respect to any one embodiment above may also be adapted to any others of the embodiments provided.

(38) This disclosure is not limited to the particular systems, devices and methods described, as these may vary. The terminology used in the description is for the purpose of describing the particular versions or embodiments only, and is not intended to limit the scope.

(39) 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 are not meant to be limiting. Other embodiments may be used, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are explicitly contemplated herein.

(40) The present disclosure is not to be limited in terms of the particular embodiments described in this application, which are intended as illustrations of various aspects. Many modifications and variations can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. Functionally equivalent methods and apparatuses within the scope of the disclosure, in addition to those enumerated herein, will be apparent to those skilled in the art from the foregoing descriptions. Such modifications and variations are intended to fall within the scope of the appended claims. The present disclosure is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled. It is to be understood that this disclosure is not limited to particular methods, reagents, compounds, compositions or biological systems, which can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.

(41) As used in this document, the singular forms a, an, and the include plural references unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. Nothing in this disclosure is to be construed as an admission that the embodiments described in this disclosure are not entitled to antedate such disclosure by virtue of prior invention. As used in this document, the term comprising means including, but not limited to.

(42) While various compositions, methods, and devices are described in terms of comprising various components or steps (interpreted as meaning including, but not limited to), the compositions, methods, and devices can also consist essentially of or consist of the various components and steps, and such terminology should be interpreted as defining essentially closed-member groups.

(43) 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. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

(44) It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as open terms (e.g., 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, etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases at least one and one or more to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles a or an limits any particular claim containing such introduced claim recitation to embodiments containing only one such recitation, even when the same claim includes the introductory phrases one or more or at least one and indefinite articles such as a or an (e.g., a and/or an should be interpreted to mean at least one or one or more); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should be interpreted to mean at least the recited number (e.g., the bare recitation of two recitations, without other modifiers, means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to at least one of A, B, and C, etc. is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., a system having at least one of A, B, and C would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to at least one of A, B, or C, etc. is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., a system having at least one of A, B, or C would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase A or B will be understood to include the possibilities of A or B or A and B.

(45) In addition, where features or aspects of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.

(46) As will be understood by one skilled in the art, for any and all purposes, such as in terms of providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc. As will also be understood by one skilled in the art all language such as up to, at least, and the like include the number recited and refer to ranges which can be subsequently broken down into subranges as discussed above. Finally, as will be understood by one skilled in the art, a range includes each individual member. Thus, for example, a group having 1-3 cells refers to groups having 1, 2, or 3 cells. Similarly, a group having 1-5 cells refers to groups having 1, 2, 3, 4, or 5 cells, and so forth.

(47) Various of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art, each of which is also intended to be encompassed by the disclosed embodiments.