Abstract: A method of manufacturing fiber optic connectors includes precision molding optical ferrule assemblies around optical fibers for use in the connectors. The optical ferrule assemblies are over-molded in two-parts: a ferrule and a hub. The ferrule is molded around a coated section of fiber and a fiber tip is formed (e.g., using a laser) at a stripped section of the optical fiber at a location axially spaced from the ferrule. The fiber is pulled into the ferrule to align the tip and the hub is formed to complete the ferrule assembly.

Abstract: The present disclosure relates to a method of fusion splicing an optical fiber. The method includes the steps of mechanically stripping a coating layer from the optical fiber to form a bare fiber end and inserting the bare fiber end of the optical fiber into a resistive heating element structure to remove residual coating from a cladding layer. The resistive heating element structure shapes a severed end of the coating layer such that the severed end is fully within a cylindrical envelope defined by a non-disturbed portion of the coating layer. The method further includes a step of loading the optical fiber into an alignment groove of a fiber alignment fixture such that the shaped severed end of the optical fiber is in contact with the alignment groove. The method includes a step of fusion splicing the bare fiber end of the optical fiber to a cable fiber.

Abstract: A method of manufacturing fiber optic connectors includes precision molding optical ferrule assemblies around optical fibers for use in the connectors. The optical ferrule assemblies are over-molded in two-parts: a ferrule and a hub. The ferrule is molded around a coated section of fiber and a fiber tip is formed (e.g., using a laser) at a stripped section of the optical fiber at a location axially spaced from the ferrule. The fiber is pulled into the ferrule to align the tip and the hub is formed to complete the ferrule assembly.

Abstract: A method of manufacturing fiber optic connectors includes precision molding optical ferrule assemblies around optical fibers for use in the connectors. The optical ferrule assemblies are over-molded in two-parts: a ferrule and a hub. The ferrule is molded around a coated section of fiber and a fiber tip is formed (e.g., using a laser) at a stripped section of the optical fiber at a location axially spaced from the ferrule. The fiber is pulled into the ferrule to align the tip and the hub is formed to complete the ferrule assembly.

Abstract: The present disclosure relates to a method of fusion splicing an optical fiber. The method includes the steps of mechanically stripping a coating layer from the optical fiber to form a bare fiber end and inserting the bare fiber end of the optical fiber into a resistive heating element structure to remove residual coating from a cladding layer. The resistive heating element structure shapes a severed end of the coating layer such that the severed end is fully within a cylindrical envelop defined by a non-disturbed portion of the coating layer. The method further includes a step of loading the optical fiber into an alignment groove of a fiber alignment fixture such that the shaped severed end of the optical fiber is in contact with the alignment groove. The method includes a step of fusion splicing the bare fiber end of the optical fiber to a cable fiber.

Abstract: A method of manufacturing fiber optic connectors includes precision molding optical ferrule assemblies around optical fibers for use in the connectors. The optical ferrule assemblies are over-molded in two-parts: a ferrule and a hub. The ferrule is molded around a coated section of fiber and a fiber tip is formed (e.g., using a laser) at a stripped section of the optical fiber at a location axially spaced from the ferrule. The fiber is pulled into the ferrule to align the tip and the hub is formed to complete the ferrule assembly.

Abstract: A method for terminating a fiber optic cable includes removing an end portion of an outer jacket of a fiber optic cable to expose a strength member and at least one optical fiber. A binder material of the strength member of the fiber optic cable is heated using a heat source to expose strength elements of the strength member. The strength elements are secured to a fiber optic connector assembly using an adhesive.

Abstract: A hybrid fiber/copper connector assembly which permits repair of damaged fibers or copper conductors carried by a hybrid fiber/copper cable without requiring replacement of the entire connector assembly or the cable is disclosed. The hybrid fiber/copper connector assembly disclosed also allows individual hybrid fiber/copper connectors of the assembly to be converted from one gender to a different gender. The hybrid fiber/copper connectors of the assembly include removable keying members mountable to housings of the connectors. The removable keying members allow gender conversion and proper mating and orientation. The hybrid fiber/copper connector assembly also allows the individual connectors of the assembly to be converted from being hybrid fiber/copper connectors to being only fiber connectors or only copper connectors.

Abstract: A tool and method for accurately and efficiently cutting through a jacket of a fiber optic cable at a break-out location. The tool securely holds the fiber optic cable and accurately controls the depth and length of cut(s). In addition, the tool accurately positions the cut(s) both in relation to the fiber optic cable and in relation to other cuts.

Abstract: A method for terminating a fiber optic cable includes removing an end portion of an outer jacket of a fiber optic cable to expose a strength member and at least one optical fiber. A binder material of the strength member of the fiber optic cable is heated using a heat source to expose strength elements of the strength member. The strength elements are secured to a fiber optic connector assembly using an adhesive.

Abstract: The present disclosure relates to a fiber optic telecommunications cable assembly including a main fiber optic cable and a tether cable that branches from the main fiber optic cable at a breakout location. The breakout location includes a breakout block mounted to the main fiber optic cable, a tether retention block mounted to the main fiber optic cable, and a sleeve positioned outside the main fiber optic cable that extends from the breakout block to the tether retention block. An optical fiber structure extends from the main fiber optic cable, through the breakout block, through the sleeve and through the tether retention block to the tether cable. The fiber optic telecommunications cable assembly also includes a tensile reinforcing structure that extends from the breakout block to the retention block for preventing a spacing between the breakout block and the retention block from exceeding a predetermined amount.

Abstract: A cable access tool and method provide a means for accurately and efficiently cutting through a jacket of a fiber optic cable at a break-out location. The cable access tool provides a means to securely hold the fiber optic cable. A means of accurately controlling the depth and length of cut(s) are provided. In addition, a means of accurately positioning the cut(s) both in relation to the fiber optic cable and in relation to other cuts is provided.

Abstract: The present disclosure relates to a fiber optic telecommunications cable assembly including a main fiber optic cable and a tether cable that branches from the main fiber optic cable at a breakout location. The fiber optic telecommunications cable assembly also includes a breakout block mounted to the main fiber optic cable at the breakout location, and an over-mold that covers the breakout block and at least a portion of the main fiber optic cable. The breakout block defines a straight-through channel in which the main fiber optic cable is received and a breakout channel that branches out from the straight-through channel. The breakout block includes seams with overlap configurations that prevent the over-mold from entering the breakout block through the seams. The breakout block also includes barrier dams for preventing bonding material from entering the breakout channel.

Abstract: The present disclosure relates to a fiber optic telecommunications cable assembly including a main fiber optic cable and a tether cable that branches from the main fiber optic cable at a breakout location. The fiber optic telecommunications cable assembly also includes a breakout block mounted to the main fiber optic cable at the breakout location, and an over-mold that covers the breakout block and at least a portion of the main fiber optic cable. The breakout block defines a straight-through channel in which the main fiber optic cable is received and a breakout channel that branches out from the straight-through channel. The breakout block includes seams with overlap configurations that prevent the over-mold from entering the breakout block through the seams. The breakout block also includes barrier dams for preventing bonding material from entering the breakout channel.

Abstract: The present disclosure relates to a fiber optic telecommunications cable assembly including a main fiber optic cable and a tether cable that branches from the main fiber optic cable at a breakout location. The breakout location includes a breakout block mounted to the main fiber optic cable, a tether retention block mounted to the main fiber optic cable, and a sleeve positioned outside the main fiber optic cable that extends from the breakout block to the tether retention block. An optical fiber structure extends from the main fiber optic cable, through the breakout block, through the sleeve and through the tether retention block to the tether cable. The fiber optic telecommunications cable assembly also includes a tensile reinforcing structure that extends from the breakout block to the retention block for preventing a spacing between the breakout block and the retention block from exceeding a predetermined amount.

Abstract: The present disclosure relates to a device for holding a plurality of fiber optic connectors. The device includes a clamp defining a plurality of ferrule receiving openings, a set plate with openings for the fibers, an alignment surface on which the ferrules rest, and an actuator for moving moveable portions of the clamp. The clamp has a plurality of moveable portions that at least partially define the ferrule receiving openings. The moveable portions are moveable between a rest, biased closed position in which the ferrules are clamped within the ferrule receiving openings, and an open position in which ferrules can be inserted in the ferrule receiving openings.

Abstract: The present disclosure relates to a device for holding a plurality of fiber optic connectors. The device includes a clamp defining a plurality of ferrule receiving openings, a set plane with openings for the fibers, an alignment surface on which the ferrules rest, and an actuator for moving moveable portions of the clamp. The clamp has a plurality of moveable portions that at least partially define the ferrule receiving openings. The moveable portions are moveable between a rest, biased closed position in which the ferrules are clamped within the ferrule receiving openings, and an open position in which ferrules can be inserted in the ferrule receiving openings.

Abstract: The present disclosure relates to a device for holding a plurality of fiber optic connectors. The device includes a clamp defining a plurality of ferrule receiving openings, a set plate with openings for the fibers, an alignment surface on which the ferrules rest, and an actuator for moving moveable portions of the clamp. The clamp has a plurality of moveable portions that at least partially define the ferrule receiving openings. The moveable portions are moveable between a rest, biased closed position in which the ferrules are clamped within the ferrule receiving openings, and an open position in which ferrules can be inserted in the ferrule receiving openings.

Abstract: The present disclosure relates to a device for holding a plurality of fiber optic connectors. The device includes a clamp defining a plurality of ferrule receiving openings, a set plate with openings for the fibers, an alignment surface on which the ferrules rest, and an actuator for moving moveable portions of the clamp. The clamp has a plurality of moveable portions that at least partially define the ferrule receiving openings. The moveable portions are moveable between a rest, biased closed position in which the ferrules are clamped within the ferrule receiving openings, and an open position in which ferrules can be inserted in the ferrule receiving openings.

Abstract: The present disclosure relates to a device for holding a plurality of fiber optic connectors. The device includes a clamp defining a plurality of ferrule receiving openings, a set plate with openings for the fibers, an alignment surface on which the ferrules rest, and an actuator for moving moveable portions of the clamp. The clamp has a plurality of moveable portions that at least partially define the ferrule receiving openings. The moveable portions are moveable between a rest, biased closed position in which the ferrules are clamped within the ferrule receiving openings, and an open position in which ferrules can be inserted in the ferrule receiving openings.