Fiber Optic Connectors and Structures for Large Core Optical Fibers and Methods for Making the Same
Fiber optic connectors and other structures that can be easily and quickly prepared by the craft for termination and/or connectorization in the field are disclosed. More specifically, the fiber optic connectors and other structures disclosed are intended for use with glass optical fibers having a large core. In one embodiment, the fiber optic connector includes a a body having a portion with a retaining structure for securing an optical fiber and a front portion having a passageway sized to receive an optical fiber and a buffer layer through a front end. Methods of making the fiber optic connectors and other structures are also disclosed. The methods disclosed allow “rough cutting” of the optical fibers with a buffer layer thereon by the craft.
This application claims the benefit of priority under 35 USC 119(e) of U.S. Provisional Application Ser. No. 61/299,105 filed on Jan. 28, 2010 and U.S. Provisional Application Ser. No. 61/251,924 filed on Oct. 15, 2009 and U.S. Provisional Application Ser. No. 61/299,091 filed on Jan. 28, 2010 and U.S. Provisional Application Ser. No. 61,251,911 filed on Oct. 15, 2009.
FIELDThe disclosure is directed to fiber optic connectors along with other structures and methods for making the same. More specifically, the disclosure is directed to fiber optic connectors and other structures for large core optical fibers and methods for making the same.
TECHNICAL BACKGROUNDOptical fiber is increasingly being used for a variety of applications, including but not limited to broadband voice, video, and data transmission. Optical fibers may be formed from different types of materials such as plastic or glass depending on the application. Typically, plastic optical fibers (POF) have been used in short distance optical networks since they are relatively easy to terminate by untrained personnel. However, POF has limitations such as not being suitable for longer distance optical networks because the losses using POF increase dramatically with the transmission distance. On the other hand, glass optical fiber has extremely wide bandwidth and low noise operation with relatively low-losses over long distances. However, terminating or connectorizing conventional glass optical fibers is more complicated than terminating POF because it usually requires special cleaving tools and/or stripping tools for preparing the optical fibers. Moreover, conventional terminations or splicing of glass optical fibers may require a skilled technician and/or specialized equipment. For instance, fiber optic connectors for conventional glass optical fibers typically have a fine polish on the end face of the ferrule holding the glass optical fiber that is best accomplished in a factory setting with dedicated equipment. Field-terminated optical fiber connectors having a mechanical splice are available to the craft but are not typically used for short distance optical networks even though they are suitable for these applications.
Thus, there is an unresolved a need for a fiber optic connectors and other structures for use with glass optical fibers that are simple, cost-effective, reliable, easy to assemble, and which offers easy connection and disconnection for short distance optical fiber networks.
SUMMARYEmbodiments of the disclosure are directed to fiber optic connectors and other structures that can be easily and quickly prepared by the craft for termination and/or connectorization in the field. More specifically, the fiber optic connectors and other structures disclosed are intended for use with glass optical fibers having a large core. Methods of making the fiber optic connectors and other structures are also disclosed. The methods disclosed allow “rough cutting” of the optical fibers with a buffer layer thereon.
Additional features and advantages will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the same as described herein, including the detailed description that follows, the claims, as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description present embodiments that are intended to provide an overview or framework for understanding the nature and character of the claims. The accompanying drawings are included to provide a further understanding of the disclosure, and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments and together with the description serve to explain the principles and operation.
Reference will now be made in detail to the preferred embodiments of the disclosure, examples of which are illustrated in the accompanying drawings. Whenever possible, like reference numbers will be used to refer to like components or parts.
The embodiments and methods described herein are suitable for making optical connections for short distance optical networks. The concepts of the disclosure advantageously allow the simple, quick, and economical connection and disconnection of glass optical fibers. Reference will now be made in detail to the preferred embodiments, examples of which are illustrated in the accompanying drawings. Whenever possible, like reference numbers will be used to refer to like components or parts.
Simply stated, special tools and procedures are not required for connectorizing and/or splicing the rough cut optical fibers. Furthermore, the structures disclosed herein are also advantageous since they allow the use of high-quality glass optical fiber without requiring polishing to a fine finish as typically done for glass optical fibers having small optical fiber cores; however, the “rough cut” end face the optical fiber/buffer layer may be smoothed if desired. Consequently, an untrained person can quickly and easily make connections of suitable quality for optical networks while advantageously using glass optical fibers, instead, of using plastic optical fibers.
Fiber optic connector 100 may include other suitable components. Illustratively,
Of course, fiber optic connectors can have other components and/or features.
For instance, fiber optic connector 200 includes a dust cap 295 attached to the same. Dust cap 295 may act as a stop for optical fiber/buffer layer assembly 20 insertion as discussed. Further, dust cap 295 may be preloaded with an index-matching gel so that when the optical fiber 10 abuts the same index-matching gel is applied to an end face of the same. As shown, dust cap 295 is secured to fiber optic connector 200 using a cantilever latch 298. Consequently, when inserting the optical fiber/buffer layer assembly 20 to the proper location abutting the dust cap 295, the dust cap 295 is inhibited from being unintentionally displaced.
One embodiment of the fiber optics connector retention structure that utilises a threaded compression nut for biasing one or more cantilever arm together to clamp the optical fiber/buffer layer assembly 20 is shown, for example in
The methods for making a fiber optic connector assembly may include the steps of providing a ferrule having a bore therethrough and a front end face and providing an optical fiber having a core and a protective layer. “Rough cutting” the optical fiber/buffer layer assembly, if necessary, and then inserting the optical fiber into the bore of the ferrule so that the core and the protective layer extend to the front end face of the ferrule. The method of making the fiber optic assembly may further include the step of abutting the optical fiber to a dust cap that includes an index-matching gel. Likewise, the method may include the step of securing the optical fiber to the connector, securing a boot to the connector, and/or the other steps described herein such as assembling the fiber optic connector. As described herein, preferably, the fiber includes a buffer layer and is cleaved or cut while retaining the buffer layer, and the cleaved or cut fiber is inserted in a connector without stripping the buffer layer. Preferably, the method includes at least one of the following: no polishing of fiber end surface, no stripping of any coatings; no use and/or no curing of adhesive(s). Preferably the cut or cleaved fiber is placed into an optical connector and anther fiber in also placed in the connector, such that the cut or cleaved fiber is optically coupled to the other fiber. Preferably, a quantity (less than 0.5 ml, preferably less than 0.1 ml) of oil or index matching gel described above is placed between the two fibers. Thus, the fibers are not attached to one another by an adhesive. Therefore, the method of making the fiber optic assembly preferably includes: no polishing of fiber end surface, no stripping of any coatings; and no curing of adhesive(s).
Alternative, methods for making a fiber optic connector assembly may includes the steps of providing a body having a portion with a retaining structure and a passageway therethrough such as schematically depicted in
One embodiment of optical fiber 10 includes: (i) a multi-mode silica based glass core having a diameter between 80-300 μm and an index of refraction n1; (ii) a cladding surrounding the core having a thickness ≦20 μm and index of refraction n2<n1 with a delta index of refraction between the core and cladding being defined as n1−n2. The cladding includes (a) fluorine doped silica with a relative index of refraction delta<0; or (b) a polymer with relative index of refraction delta<0; (iii) a protective coating having a Young's modulus greater than 700 MPa, a thickness ≦15 μm, and an index of refraction index of refraction n3>n2. Further, optical fiber 10 includes a buffer layer 18 as discussed herein.
A more specific variation of optical fiber 10 may include a glass core with a graded index with a 175 μm to 225 μm diameter where the cladding is a fluorinated polymer and has a thickness between 10 μm to 15 μm, and the protective coating having the a thickness of ≦10 μm. Additionally, the buffer layer 18 may have a shore D hardness of at least 60.
One advantage of the disclosed optical fibers is that the protective coating minimizes the fiber movement inside the buffer layer during “rough cutting” and also during subsequent use in the fiber optic connector, due to strong adhesion of the protective coating to both the cladding and the buffer layer. Yet another advantage the optical fibers disclosed is that the protective coating prevents the optical fiber core from moving off-center during “rough cutting”, thus minimizing coupling losses when this fiber is coupled to another optical fiber. Yet another advantage of the optical fibers disclosed is that the protective coating also provides protection during handling and storage if the buffer layer is not applied at the same time as the protective coating.
Although the disclosure has been illustrated and described herein with reference to preferred embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples can perform similar functions and/or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the disclosure and are intended to be covered by the appended claims. It will also be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the same. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
Claims
1. A fiber optic connector, comprising:
- a body of the fiber optic connector having a portion with a retaining structure for securing an optical fiber and a front portion having a passageway sized to receive an optical fiber and a buffer layer through a front end, wherein the fiber optic connector allows the optical fiber and the buffer layer to extend to a mating front face of the fiber optic connector.
2. The fiber optic connector of claim 1, further including an optical fiber with a buffer layer, wherein the buffer layer is secured by the retaining structure.
3. The fiber optic connector of claim 2, wherein optical fiber is a silica-based optical fiber
4. The fiber optic connector of claim 2, wherein optical fiber is not polished to a fine finish.
5. The fiber optic connector of claim 2, further including a boot, wherein the boot applies a forward biasing force to the optical fiber.
6. The fiber optic connector of claim 2, wherein optical fiber has a core that is 80 microns or greater.
7. The fiber optic connector of claim 2, wherein the optical fiber has a protective coating with a Young's modulus greater than 700 MPa and a thickness of 15 microns or less.
8. The fiber optic connector of claim 1, wherein the retaining structure is formed by one or more cantilevered arms and a clamping structure for biasing the one or more cantilevered arms toward each other.
9. The fiber optic connector of claim 8, wherein the clamping structure includes a boot, a crimp, or a cam, or a cantilever arm structure with a threaded compression nut.
10. The fiber optic connector of claim 1, wherein the retaining structure is reversible.
11. The fiber optic connector of claim 1, wherein the passageway has a diameter of about 250 microns or greater.
12. The fiber optic connector of claim 1, further including a dust cap that acts as a stop for insertion of the optical fiber.
13. The fiber optic connector of claim 1, further including a dust cap having an index matching gel therein.
14. The fiber optic connector of claim 1, the inner housing further including a grommet at the front end.
15. A method for making a fiber optic connector assembly, comprising:
- providing a body having a portion with a retaining structure and a passageway therethrough;
- providing an optical fiber having a core and a protective layer; and
- inserting the optical fiber into the passageway of the body so that the core and the protective layer extend to a mating front face of the fiber optic connector; and
- securing the optical fiber to the fiber optic connector.
16. The method of claim 15, further including the step of securing a boot to the inner housing.
17. The method of claim 15, the retaining structure including one or more cantilevered arms.
18. The method of claim 15, wherein optical fiber is a silica-based optical fiber and not polished.
19. The method of claim 15, wherein optical fiber has a core that is 80 microns or greater.
20. The method of claim 15, the step of inserting further including abutting the optical fiber to a dust cap that includes an index matching gel.
21. The method of claim 15, the fiber optic connector further including a latching mechanism.
22. The method according to claim 15, further comprising inserting said cleaved or cut fiber in a connector without stripping said buffer.
23. The method according to claim 22, wherein said method includes at least one of the following: no polishing of fiber end surface, no stripping of any coatings; no curing of adhesive(s).
24. The method according to claim 22, wherein said method includes placing said cut or cleaved fiber into an optical connector; placing anther fiber in said connector, wherein said cut or cleaved fiber is optically coupled to said another fiber.
25. The method according to claim 22, including placing a quantity of gel between said fibers.
26. The method according to claim 25, wherein said fibers are not attached to one another by an adhesive.
27. A mechanical splice body, comprising:
- a tube having a having a passageway between a first end and a second end, the passageway sized for receiving a first optical fiber having a buffer layer into the first end and a second optical fiber having a buffer layer into the second end; and
- a first retaining structure; and
- a second retaining structure.
28. A method for making a fiber optic connection, comprising:
- providing a mechanical splice body having a first end, a second end, and a bore therethrough;
- providing a first optical fiber having a core and a protective layer;
- providing a second optical fiber having a core and a protective layer;
- inserting the first optical fiber into the bore from the first end so that the core and the protective layer are disposed within the bore; and
- inserting the second optical fiber into the bore from the second end so that the core and the protective layer are disposed within the bore and the second optical fiber abuts the first optical fiber, thereby making an optical connection.
Type: Application
Filed: Oct 11, 2010
Publication Date: Apr 21, 2011
Inventors: Seldon David Benjamin (Painted Post, NY), Michael de Jong (Colleyville, TX), Radawan Hall (Granite Falls, NC), Micah Colen Isenhour (Lincolnton, NC), Dennis Michael Knecht (Hickory, NC), James Phillip Luther (Hickory, NC), Randy LaRue McClure (Corning, NY)
Application Number: 12/901,720
International Classification: G02B 6/36 (20060101); G02B 6/00 (20060101); G02B 6/26 (20060101);