Abstract: A fiber optic cable and methods of manufacturing the same includes at least one optical fiber, and at least one ferrule. The at least one ferrule is attached to the at least one optical fiber before the cable jacket is applied. The cable jacket surrounds the at least one optical fiber and the at least one ferrule so that when the cable jacket is opened the at least one optical fiber having the at least one ferrule attached may be accessed. Consequently, the when opening the cable, the craft is presented with an optical fiber that is preterminated with a ferrule. Optionally, the ferrule can have a cover or be a portion of a fiber optic connector. The cable is manufactured so that one or more of the ferrules are appropriately placed along the length of the fiber optic cable for distribution into the fiber optic network.

Abstract: A precision mold insert and method for manufacturing angled or angled and bumpered multi-fiber ferrules. The precision mold insert includes an angled end face forming portion, one or more optional bumper forming portions, one or more fiber bores for receiving one or more fiber bore forming pins, and one or more guide pin holes for receiving one or more guide pin hole forming pins. A method for manufacturing a precision mold insert for molding angled or angled and bumpered multi-fiber ferrules utilizing electrical discharge machining (EDM) process and/or a poly crystalline diamond (PCD) grinding tool is provided. The mold insert is used to produce a multi-fiber ferrule having a pre-molded angled end face that is not machined, polished or otherwise altered subsequent to the molding process. The ferrule may also include bumpers for polishing end portions of optical fibers positioned within the fiber bores without altering the angled end face.

Abstract: A flexible cross-connect apparatus for cross-connecting fiber optic cables includes a transition strength member, at least one cable clamp assembly, at least one fiber storage device, and a cover for protecting the cross-connect apparatus. The cross-connect apparatus is flexible about a preferential bending plane because the transition strength member includes a preferential bending plane for influencing bending. The at least one cable clamp assembly is used for securing one or more cables with the transition strength member at the ends. In one embodiment, a splice carriage is removably attached to the transition strength member for aiding the craftsman to work at a splicing station.

Abstract: A distribution fiber optic cable including a plurality of optical fibers, a plurality of tubes, at least one filling component, and least one access location, and a cable jacket. Each tube has at least one optical fibers therein, where some of the plurality of tubes are stranded together over at least a portion of the longitudinal length of the fiber optic cable, thereby forming at least a portion of a cable core. The access location includes at least one access tube. The one access tube being one of the plurality of tubes that transitions during manufacturing from a first location within the cable core to a second location apart from the cable core and the at least one filling component is introduced into the cable core for taking the position of the access tube within the cable core. Also disclosed are cable assemblies.

Abstract: A method for manufacturing a distribution fiber optic cable is disclosed. The method comprises the steps of providing a plurality of optical fibers for a cable core. Transitioning at least one of the plurality of optical fibers between a first location and a second location, where one of the locations is disposed within the cable core and the other location is disposed apart from the cable core and applying a cable jacket. In other embodiments, the cable can be a portion of a cable assembly.

Abstract: A guide block assembly for aligning and retaining fiber bore forming pins and guide pin bore forming pins in precise relation to each other during the molding of a multi-fiber ferrule includes a unitary member defining at least one fiber bore and at least one guide pin bore. Each fiber bore, and optionally each guide pin bore, is formed by creating a starter hole using a first electric discharge machining (EDM) wire and enlarging the starter hole using a second EDM wire. Each fiber bore has a length to diameter ratio of between approximately 3:1 to 10:1, more preferably between approximately 4:1 to 8:1, and most preferably approximately 6:1. The guide block assembly may further include a cavity behind the fiber bore and a front face that forms a non-rectilinear surface on the face of the ferrule. The unitary block assembly contains fewer parts and is less expensive to manufacture.

Abstract: A multi-fiber ferrule is configured to accept coated optical fibers and an optical fiber ribbon. The multi-fiber ferrule includes an optical fiber receiving portion, a lead-in portion, and an alignment portion. The alignment portion includes a buffered fiber alignment portion to orient and separate buffered optical fibers. The alignment portion may also include a ribbon alignment portion to orient and align the optical fibers of an optical fiber ribbon. As a result, the stripped optical fibers of both the coated optical fibers and the optical fiber ribbon are guided and aligned with the optical fiber bores provided in the optical fiber receiving portion of the multi-fiber ferrule.

Abstract: The method and apparatus of the present invention is capable of precisely determining the orientation of the axis of the guide pin hole defined by a multifiber ferrule. Since the axis of the guide pin hole has a direct relationship to the alignment of the optical fibers, the method and apparatus can also precisely determine the end face angle of the ferrule based upon the axis of the guide pin hole without reference to external features of the ferrule. A measurement pin is initially positioned in a guide pin hole such that a first end of the measurement pin is disposed proximate the end face of the ferrule. The reference plane defined by the first end of the measurement pin is then measured, such as by an interferometer. Based upon the reference plane and the predetermined angle between the reference plane and the axis of the guide pin hole, the method and apparatus can precisely determine the orientation of the axis of the guide pin hole.

Abstract: A guide block assembly for aligning and retaining fiber bore forming pins and guide pin bore fanning pins in precise relation to each other during the molding of a multi-fiber ferrule includes a unitary member defining at least one fiber bore and at least one guide pin bore. Each fiber bore, and optionally each guide pin bore, is formed by creating a starter hole using a first electric discharge machining (EDM) wire and enlarging the starter hale using a second EDM wire. Each fiber bore has a length to diameter ratio of between approximately 3::1 to 10::1, more preferably between approximately 4::1 to 8::1, and most preferably approximately 6::1. The guide block assembly may further include a cavity behind the fiber bore and a front face that forms a non-rectilinear surface on the face of the female. The unitary block assembly contains fewer parts and is less expensive to manufacture.

Abstract: A ferrule is provided that has an exterior surface that can be defined with sufficient precision to serve as a datum during subsequent polishing operations. The ferrule includes first and second ferrule body portions that are joined along a parting line. The first ferrule body portion has a first width and the second ferrule body portion has a second width that is less than the first width, such as by at least 50 microns. In addition, the width of the first ferrule body portion is defined to be within a first tolerance, while the width of the second ferrule body is defined to be within a second tolerance that is larger than the first tolerance. As such, the first ferrule body portion is not only larger than the second ferrule body portion, but the first ferrule body portion is also more precisely defined. Thus, only one portion of the ferrule of the present invention needs to be precisely defined. A mold for forming the ferrule and a method of fabricating the ferrule are also provided.

Abstract: A method and apparatus precisely determines the orientation of the axis of a guide pin hole defined by a multifiber ferrule, and therefrom, precisely determines an end face angle of the ferrule without reference to external features of the ferrule. A measurement pin is positioned in the guide pin hole with a first end disposed proximate the end face of the ferrule. A reference plane defined by the first end of the measurement pin is measured. The orientation of the axis of the guide pin hole is determined based upon the predetermined angle between the axis of the guide pin hole and the reference plane. A plane defined by at least a portion of the end face of the ferrule is then measured. The end face angle is precisely determined based upon the angular difference between the reference plane and the plane defined by the end face of the ferrule.

Abstract: A universal ferrule for use within a plurality of optical fiber connector types includes a longitudinally extending ferrule body having an opposing end face and base. The ferrule body defines an internal passageway at the base and at least one bore at the end face. The base is sized and shaped to engage an internal chamber within the housing of each connector type to rotationally, radially and longitudinally position the at least one bore relative to the connector housing. The ferrule body has a cylindrical external surface that includes at least one longitudinal groove. A first groove portion adjacent the end face is sized and shaped to position the universal ferrule relative to a mating ferrule. A second groove portion adjacent the base is larger than the first groove portion. A chamfered edge between the end face and the external surface of the ferrule body facilitates interconnection of mating ferrules.

Abstract: A guide block assembly is provided for retaining fiber bore forming pins and guide pin bore forming pins in precise relation to each other during the molding of a ferrule used in a multi-fiber connection. The assembly may include a top portion and a bottom portion with corresponding fiber and guide pin bore grooves formed on a surface of the top and bottom portions. When the top and bottom portions are assembled, the corresponding fiber and guide pin bore grooves form fiber and guide pin bores, respectively. The assembly may also include another portion that form additional bores with either the top or the bottom portion. A method of fabricating and aligning the guide block assembly is also disclosed.

Abstract: A preassembled multifiber connector is provided that includes a connector housing and a windowless multifiber ferrule that is substantially rectangular in lateral cross-section. The windowless multifiber ferrule can be at least partially disposed within an internal cavity defined by the connector housing to thereby form a multifiber connector that is free of optical fibers. Thus, the multifiber connector is capable of being preassembled prior to inserting the plurality of optical fibers into the optical fiber bores defined by the windowless multifiber ferrule. A corresponding method of preassembling a multifiber connector is therefore also provided according to the present invention. A ferrule is also provided that is capable of being selectively converted from a windowless configuration to a windowed configuration. The ferrule of this embodiment includes a ferrule body that not only defines at least one optical fiber bore, but that also defines a well extending through a side surface of the ferrule body.

Abstract: A preassembled multifiber connector is provided that includes a connector housing and a windowless multifiber ferrule that is substantially rectangular in lateral cross-section. The windowless multifiber ferrule can be at least partially disposed within an internal cavity defined by the connector housing to thereby form a multifiber connector that is free of optical fibers. Thus, the multifiber connector is capable of being preassembled prior to inserting the plurality of optical fibers into the optical fiber bores defined by the windowless multifiber ferrule. A corresponding method of preassembling a multifiber connector is therefore also provided according to the present invention. A ferrule is also provided that is capable of being selectively converted from a windowless configuration to a windowed configuration. The ferrule of this embodiment includes a ferrule body that not only defines at least one optical fiber bore, but that also defines a well extending through a side surface of the ferrule body.

Abstract: A ferrule is provided that defines a shoulder having curved corners. In this regard, the ferrule includes a lengthwise extending shaft and an enlarged rear portion proximate the shaft. The rear portion is larger in lateral cross-section than the shaft to thereby define a shoulder. In addition, that portion of the shaft proximate the enlarged rear portion includes curved corners such that the shoulder has corresponding curved inner corners. A fiber optic connector housing is also provided that defines an inwardly projecting shoulder having curved corners. The fiber optic connector housing includes a forward segment defining a lengthwise extending passage and a rearward segment also defining a lengthwise extending passage. The lengthwise extending passage defined by the rearward segment is larger in lateral cross-section than the lengthwise extending passage defined by the forward segment such that a shoulder is defined at the intersection of the forward and rearward segments.

Abstract: A ferrule is provided that defines a shoulder having curved corners. In this regard, the ferrule includes a lengthwise extending shaft and an enlarged rear portion proximate the shaft. The rear portion is larger in lateral cross-section than the shaft to thereby define a shoulder. In addition, that portion of the shaft proximate the enlarged rear portion includes curved corners such that the shoulder has corresponding curved inner corners. A fiber optic connector housing is also provided that defines an inwardly projecting shoulder having curved corners. The fiber optic connector housing includes a forward segment defining a lengthwise extending passage and a rearward segment also defining a lengthwise extending passage. The lengthwise extending passage defined by the rearward segment is larger in lateral cross-section than the lengthwise extending passage defined by the forward segment such that a shoulder is defined at the intersection of the forward and rearward segments.

Abstract: A multifiber ferrule is provided that includes a ferrule body that defines at least one elongate hole opening through the front face of the ferrule body that, in turn, includes a lead-in portion proximate the front face for guiding the respective alignment member into the elongate hole. The ferrule body at least partially defines one or more elongate holes, such as a guide pin hole or an alignment groove, each having a longitudinal axis extending therethrough. Each elongate hole includes the lead-in portion proximate the front face and an adjacent alignment portion. The lead-in portion expands radially outward from the longitudinal axis in a direction extending from the adjacent alignment portion to the front face of the ferrule body. As such, the opening of the lead-in portion through the front face of the ferrule body is larger in lateral cross-section than the opening of the lead-in portion into the adjacent alignment portion.

Abstract: An alignment sleeve for precisely aligning a pair of ferrules, such as a pair of multifiber ferrules, is provided along with an associated assembly method. The alignment sleeve includes a sleeve member defining a lengthwise extending cavity opening through opposed ends thereof. The sleeve member can also define at least one window and, more commonly, a plurality of windows opening into the cavity. The alignment sleeve also includes a guide pin extending lengthwise through the cavity and a guide pin engagement member extending at least partially into the window defined by the sleeve member. The guide pin engagement member is bonded, such as by welding, to the guide pin such that the guide pin is retained in a floating relationship within the sleeve member. The sleeve member can also define an expansion window to accommodate expansion of the guide pin that is creating during welding of the guide pin.

Abstract: An adapter assembly is provided for removably receiving two optical fiber ferrules of the type with open grooves extending longitudinally rearward of the end face of the ferrule. The assembly comprises a sleeve with an interior surface that defines a passageway therethrough sized for receiving the ends of the ferrules therein. The interior surface also defines two longitudinal grooves opposite each other that open to the passageway. A guide pin is located in each groove such that an exposed portion of the outer surface of the guide pin along the entire length of the guide pin inside the sleeve is exposed to the passageway. The exposed portion are sized and located relative to each other to slide in the ferrule grooves and operatively align the end faces of the ferrules rotationally and laterally relative to each other when the two ferrules are inserted into the sleeve.