Formed septum joint in cover of closure / housing of fiber optic cable

Abstract

Fiber optic cable enclosures and methods of forming fiber optic cable enclosures are disclosed. The closure includes a housing having a base and a cover. The cover includes a plurality of ports, each port sized to receive an associated drop cable. A septum assembly joins an associated connector to an associated optical fiber, and the septum assembly includes a body formed as part of a housing cover. Preferably, the outer periphery of the body is molded to the housing cover to form an integrated component, eliminating a component such as a separate seal between the body and the cover.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of priority to U.S. Provisional Application No. 63 / 388,459, filed on July 12, 2022, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] The present disclosure relates to fiber optic closures or housings and, more particularly, to an integrated molded bulkhead connector for use in a closure cover. Background Art

[0004] Fiber optic closures are widely used in the telecommunications industry (e.g., for fiber optic cables) and provide flexibility, reliability, and a compact footprint to encourage quick and easy customer introduction installation in a variety of applications. These types of closures are generally available in a variety of forms and may include different numbers of ports (2, 4, 6, 8, and 12 port terminals), different mounting options, etc. to meet specific network requirements. Standard fiber optic connectors (e.g., applicant's own commercial The fiber optic connector is connected to the enclosure through the fiber access bulkhead. Hardened connector and lead-in components make the interconnection highly resistant to wear and tear.

[0005] Environmentally protected connector and entry assembly allow for quick and easy user entry. Unique re-entry housing allows easy access to fiber optic connectors. Mounting capability allows for use in a variety of network applications or designs (e.g., aerial, pole, pedestal, or underground / vault installations). Flat or round drop cables can be accommodated, drop cables can be factory terminated or field installed. Enclosure cover can accommodate bulkhead adapters, such as Applicant's own commercial Bulkhead adapter. The closure base has a center strength member clip that secures the input fiber to the closure. The base also preferably has a slack management bracket to properly route the fiber on the inside of the closure.

[0006] A need exists for improved arrangements that provide at least one or more of the features described above as well as other features and benefits. Summary of the invention

[0007] The fiber optic cable closure includes a housing having a base and a cover. The cover has a plurality of ports, each port being sized to receive an associated drop cable. A bulkhead assembly connects an associated connector to an associated optical fiber, and the bulkhead assembly includes a body formed as part of the housing cover.

[0008] The outer periphery of the body of the partition assembly is preferably formed as part of the housing cover.

[0009] More preferably, the body and the housing cover are integrally formed.

[0010] The partition assembly includes (i) a cover subassembly that forms an interface between associated optical fibers received through opposite ends thereof; (ii) a flange that receives a first end of the cover subassembly, the flange being received in one end of a body; and (iii) a seal that is received on the flange and is used to seal between the flange and the body.

[0011] A method of forming a fiber optic cable enclosure includes providing a housing including a base and a cover. The cover includes a plurality of ports, each port being sized to receive an associated drop cable. The method also includes providing a bulkhead assembly for coupling an associated connector to an associated optical fiber, and including a body as part of the bulkhead assembly. The method also includes forming the body of the bulkhead assembly as part of the housing cover.

[0012] The body forming step includes forming an outer periphery of a body of the separator assembly as part of the housing cover.

[0013] The body forming step preferably includes integrally forming the body with the housing cover.

[0014] The method also includes (i) providing a covering subassembly that forms an interface between associated optical fibers received through opposite ends thereof, (ii) including a flange that receives a first end of the covering subassembly, the flange being received in one end of a body, and (iii) receiving a seal on the flange for sealing between the flange and the body.

[0015] One benefit of the new closure and associated method relates to a reduction in the number of parts (at least three fewer parts) in the bulkhead assembly when compared to the number of parts used in prior art bulkhead assemblies by integrally forming the body with the closure cover.

[0016] Another advantage resides in reduced assembly time.

[0017] Yet another benefit is the reduced likelihood associated with incorrect assembly, thereby improving quality control.

[0018] Yet another advantage results in the elimination of manufacturing and inventory problems previously associated with these multiple parts.

[0019] The possibility of water ingress is also reduced.

[0020] Other benefits and advantages of the present disclosure will become more apparent upon reading and understanding the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] FIG. 1 is a perspective view of a prior art fiber optic cable closure or housing.

[0022] FIG. 2 is a bottom plan view of the closure of FIG. 1 .

[0023] FIG. 3 is a front elevational view of the closure of FIG. 1 .

[0024] 4 is a perspective view of a conventional hardened connector coupler with a dust cap shown affixed thereto.

[0025] 5 is a perspective view of a prior art bulkhead adapter assembly with a dust cap shown closed on one end thereof.

[0026] 6 is a perspective view of the bulkhead adapter assembly of FIG. 5 with the dust cap shown removed and attached to the body.

[0027] 7 is an exploded view of the various components of the bulkhead adapter assembly of FIG. 5 .

[0028] 8 is a rear perspective view of the body of the adapter assembly of FIG. 7 .

[0029] Fig. 9 and Fig.10 are perspective views of the new closure or housing taken from the top and right side and the top and left side respectively.

[0030] Fig.11 is a perspective view of the underside of the closure disassembled from the base member (not shown).

[0031] Fig.12 yes Fig. 9 Front elevation view of the enclosure.

[0032] Fig.13 yes Fig. 9 Side elevation view of the enclosure.

[0033] Fig.14 yes Fig. 9 A top plan view of the closure.

[0034] Fig.15 yes Figure 9-14 An exploded perspective view of the components of a closure. DETAILED DESCRIPTION

[0035] The following description with reference to the accompanying drawings provides assistance for a comprehensive understanding of one or more embodiments of the present disclosure as defined by the claims and their equivalents. It includes various specific details to assist understanding, but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications to the various embodiments described herein may be made without departing from the scope and spirit of the present disclosure. The various exemplary embodiments of the present disclosure are not limited to the specific details of the different embodiments, and should be interpreted as including all variations and / or equivalents or substitutes included in the ideas and technical scope of the attached claims. When describing the drawings, similar reference numerals are used for similar elements where possible.

[0036] The terms "include" or "may include" used in the present disclosure indicate the existence of the corresponding functions, operations, elements and the like disclosed, and do not limit the additional one or more functions, operations, elements and the like. In addition, it should be understood that the terms "include", "comprise", "have" or "have" used in the present disclosure indicate the existence of the components, features, numbers, steps, operations, elements, parts or combinations thereof described in the specification, and do not exclude the existence or addition of one or more other features, numbers, steps, operations, elements, parts or combinations thereof.

[0037] The terms "or" or "at least one of A or / and B" used in the present disclosure include any and all combinations of the words listed therein. For example, "A or B" or "at least one of A or / and B" means including A, including B, or including A and B.

[0038] Although the terms used in the present disclosure, such as "first" and "second", can modify various elements of different exemplary embodiments, these terms do not limit the corresponding elements. For example, these terms do not limit the order and / or importance of the corresponding elements, nor do these terms exclude additional elements (e.g., second, third, etc.). Terms can be used to distinguish one element from another. For example, a first mechanical device and a second mechanical device both indicate mechanical devices and can indicate different types of mechanical devices or the same type of mechanical devices. For example, without departing from the scope of various exemplary embodiments of the present disclosure, a first element can be named as a second element, and similarly, a second element can also be named as a first element.

[0039] It is understood that when an element is referred to as being "connected" or "coupled" to another element, the element may be directly connected or coupled to the other element, and there may be an intermediate element between the element and the other element. Conversely, it is understood that when an element is referred to as being "directly connected" or "directly coupled" to another element, there are no intermediate elements between the element and the other element.

[0040] The terms used in various exemplary embodiments of the present disclosure are only used for the purpose of describing specific exemplary embodiments and are not intended to limit various exemplary embodiments of the present disclosure. As used herein, singular forms are also intended to include plural forms, unless the context clearly indicates otherwise.

[0041] All terms including technology or science used herein have the same meaning as commonly understood by ordinary technicians in the relevant technical field unless they are otherwise defined. Terms defined in commonly used dictionaries should be interpreted as having the same meaning as the contextual meaning of the relevant technology, and should not be interpreted as having inconsistent or exaggerated meanings unless they are clearly defined in various exemplary embodiments.

[0042] A prior art closure or housing assembly 100 for a fiber optic cable 102 is shown in FIGS. 1-3. Input and output fiber optic cables 102a, 102b are respectively secured to a base member 104 of the closure assembly 100. A cover 106 of the closure assembly 100 surrounds an interior cavity that provides desired slack storage and protects interconnections formed in a splice tray (not shown) between individual optical fibers (not shown) of the fiber optic cable 102 and individual drop wires 110 (FIG. 4). The drop wires 110 include dust caps 112 connected to the drop wires by tethers 114. When the dust caps 112 are removed, the terminal ends 116 of the drop wires are inserted into adapter assemblies or bulkhead assemblies 120. Four bulkhead assemblies 120 are illustrated in FIGS. 1-3, but as is well known in the art, more or fewer bulkhead assemblies may be provided in the cover 106 of the closure assembly 100. One of the prior art bulkhead assemblies is shown in FIG. 5 and includes a dust cap 122 mounted thereto on an outer end thereof. 6, dust cap 122 is shown removed and connected to the outer end of bulkhead assembly 120 by tether 124. When dust cap 122 of bulkhead assembly 120 is removed, it provides access to a recess that is sized to receive terminal end 116 (FIG. 4) of lead-in wire 110. Although a bonded connection is not shown, the lead-in wire 110 and dust caps 112, 122 of bulkhead assembly 120 are preferably bonded together (e.g., threaded together) when terminal end 116 of lead-in wire 110 is received and fixedly mounted in the bulkhead assembly.

[0043] In FIG. 7 , the baffle assembly 120 is shown in an exploded perspective view, particularly illustrating various components that comprise a preferred arrangement of the baffle assembly. In the prior art, similar baffle assemblies are shown and described as being connected to closure assemblies of different configurations, for example, as shown and described in US 5,778,122 and US 7,653,282, the entire disclosure of which is expressly incorporated herein by reference. As shown in FIG. 7 , a preferred form of the adapter assembly or baffle assembly 120 includes at least the following components. A body 130 (also shown in FIG. 8 ) receives first and second seals 132, 134 at its first end, the size of which is formed to receive and be installed in the opening / port of the cover 106 of the closure assembly 100. An internally threaded nut 136 ( FIG. 7 ) is also received on the first end of the body 130 and is threadedly coupled to the external threads on the body to maintain the seals 132, 134 in the assembled position. A cover 138 is also received on the first end of the body 130 and abuts against the nut 136.

[0044] A cover subassembly 150 (FIG. 7) is received in the body 130 and provides a primary interface between optical fibers received through opposite ends of the bulkhead assembly 120. A flange 152 receives a front end of the cover subassembly 150 therein, and the flange is received at an opposite second end of the body 130. When the components of the bulkhead assembly 120 are assembled together, a third seal 154 is received on the flange 152 and sealingly interconnects the flange with the body 130. As is also apparent in FIG. 7, the flange 152 is internally threaded at one end to threadably receive the removable cap 122 therein. Additionally, a fourth seal 156 is received on the cap 122 to provide a sealing interface between an outer diameter of the insertion end of the cap and an inner diameter portion of the flange 152.

[0045] Next go to Figure 9-14 , an improved closure assembly 200 is shown with the generally planar base member removed for ease of illustration, although it is understood that the closure assembly will include the base member. For ease of reference, like reference numerals in the 200 series are used to refer to like parts where appropriate, e.g., the body 130 of the prior art arrangement described in FIGS. 1-8 and Figure 9-151-3. However, here, the cover 206 is modified to include a portion of the baffle assembly as part of the cover, preferably an integrated portion (e.g., integrally formed) for sealingly coupling the lead-in wire (not shown) to the closure assembly 200. Specifically, each port 208 is modified to include a body 230 as part thereof, preferably integrally formed with the cover so that the cover and the body are one component. Each body 230 is configured similar to the body 130 shown separately in Figure 8 and as part of the assembly views of Figures 5 and 6 and the exploded view of Figure 7. Here, in accordance with the teachings of the present disclosure, each body 230 is formed to the cover and is preferably formed as an integrated portion of the cover 206, and the size of each body 230 is still formed to receive a corresponding cover subassembly (not shown for ease of illustration). Although the four ports 208 are in Figure 9-15 1-8, the closure assembly 120 is shown in the cap 206 of the closure assembly 200. Again, it will be appreciated by those skilled in the art that a greater or lesser number of ports, and likewise an integrated body 230, may be provided to form part of a separate bulkhead assembly. By preferably forming the body 230 integrally with the cap 206, greater precision may be achieved in the overall assembly, and the accumulated tolerances associated with assembling multiple components into an assembly may also be reduced thereby. When compared to the bulkhead assembly 120 of the prior art arrangement of FIGS. 1-8, the bulkhead assembly 120 of FIGS. 1-8 may be provided in the embodiment of the present invention. Figure 9-15 The diaphragm assembly 220 in the embodiment of the present invention requires a reduced, fewer number of parts. In particular, several parts are eliminated in this integrated body 230 molded to the cover 206, that is, the first and second seals or O-rings 132, 134 and the threaded nut 136 shown and used in FIG. 7 are eliminated and do not need to be incorporated into the Figure 9-15 In addition, the reduced number of components also improves quality control because the seal will not be accidentally overlooked in the case of the integrally formed body 230 and cover 206. For ease of explanation, Fig.15 The integrated body 230 is illustrated as a "separate" component, although those skilled in the art will appreciate that as described above and Figure 9-14 7, the body 230 is actually molded (i.e., preferably integrally formed / molded with the cover) to the cover 206. The integrated body 230 is not a non-integrated component separate from the cover 206; however, this is only for ease of illustration and comparison with the prior art arrangement of FIG. 7. Specifically, in FIG. 7, the body 130 is separately formed and then assembled or mounted to the cover 106. In the present disclosure, those skilled in the art will understand that the body 230 is made as part of the cover 206, i.e., preferably molded with the cover to form an integrated, one-piece structure, such as Fig.15206, which receives the remaining components of the baffle assembly 220. In particular, the integrally formed body 230 extending beyond the outer surface of the cover 206 is Fig. 9 , Fig.10 and Figure 12-14 1-8, is similar in size to the extent of the axial extension of the separately formed body 130. Fig.11 Also illustrated is the accessibility of the inner surface of the integrally formed body 230 , with the inner receiving end of the body 230 extending inwardly into the cavity of the fiber optic cable closure / housing 200 .

[0046] When compared to the number of components used in the prior art baffle assembly 120 of FIGS. 1-8, Figure 9-15 The reduced number of components (at least three components) in the bulkhead assembly 220 of the integrally formed body 230 advantageously reduces assembly time, reduces the likelihood of incorrect assembly, thereby improving quality control, and also eliminates manufacturing and inventory issues previously associated with these multiple components. Further, due to the reduction of tolerance stack-up issues, water ingress is reduced in the new closure assembly 200 when compared to the prior art closure assembly 100 arrangement.

[0047] This written description uses examples to describe the disclosure, including the best mode, and also to enable any person skilled in the art to make and use the disclosure. Other examples that occur to those skilled in the art are considered to be within the scope of the invention if they have structural elements that are not different from the same concept or from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the same concept or from the literal language of the claims. In addition, the disclosure is considered to seek protection for combinations of components and / or steps and combinations of claims as initially shown for examination, and to seek potential protection for other combinations of components and / or steps and combinations of claims during prosecution.

[0048] Although specific advantages have been listed above, various embodiments may include some, none, or all of the advantages listed. Although exemplary embodiments are illustrated in the figures and descriptions herein, the principles of the present disclosure may be implemented using any number of technologies, whether currently known or unknown. In addition, the operation of the systems and devices disclosed herein may be performed by more or less or other components, and the methods described herein may include more or less or other steps. In addition, the steps may be performed in any suitable order.

[0049] To assist the Patent Office and any reader of this application and any patent resulting therefrom in interpreting the appended claims, Applicants do not intend that any of the appended claims or claim elements invoke 35 U.S.C. 112(f) unless the words “means for” or “step for” are expressly used in a particular claim.

Claims

1. An optical fiber cable closure, comprising: a housing having a base and a cover, the cover including a plurality of ports, each port sized to receive an associated drop cable; as well as A bulkhead assembly for coupling an associated connector to an associated optical fiber includes a body formed as part of a housing cover.

2. The closure of claim 1 wherein the periphery of the body of the baffle assembly is formed as part of the housing cover.

3. The closure of claim 2, wherein the body is integrally formed with the housing cover.

4. A closure according to claim 1, wherein the partition assembly includes (i) a cover subassembly that forms an interface between associated optical fibers received through opposite ends thereof; (ii) a flange that receives a first end of the cover subassembly, the flange being received in one end of the body; and (iii) a seal that is received on the flange and is used to seal between the flange and the body.

5. The closure of claim 4 wherein the periphery of the body of the diaphragm assembly is integrally molded to the outer cover such that the separate seal is eliminated between the body and the cover.

6. A method of forming a fiber optic cable closure, comprising: providing a housing including a base and a cover, the cover including a plurality of ports, each port sized to receive an associated drop cable; providing a bulkhead assembly for coupling an associated connector to an associated optical fiber, the bulkhead assembly comprising a body; and The body of the baffle assembly is formed as part of the housing cover.

7. The method of claim 6, wherein the body forming step includes forming an outer periphery of a body of the baffle assembly as part of the housing cover.

8. The method of claim 7, wherein the body forming step includes integrally molding the body with the housing cover.

9. The method of claim 6 further includes (i) including a covering subassembly that forms an interface between associated optical fibers received through opposite ends thereof; (ii) including a flange that receives a first end of the covering subassembly, the flange being received in one end of the body; and (iii) receiving a seal on the flange for sealing between the flange and the body.

10. The method of claim 9, wherein the body forming step includes integrally molding an outer periphery of the body of the partition assembly with the housing cover.

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