Integrated connector cable

Abstract

The invention relates to an integrated connector cable. An optical cable includes an optical component assembly, inner and outer optical fibers, a component cover, and a connector. The optical component assembly includes an optical unit. The inner optical fiber and the outer optical fiber are on opposite sides of the optical unit such that the optical unit receives a first optical signal from the inner optical fiber and the outer optical fiber receives a second optical signal from the optical unit, or such that the optical unit receives the second optical signal from the outer optical fiber and the inner optical fiber receives the first optical signal from the optical unit. The component cover encapsulates an entirety of the optical unit and a portion of the inner optical fiber and a portion of the outer optical fiber. The connector includes a portion of the first external optical fiber that is exposed to route the second optical signal.

Description

[0001] This application is a divisional application of Chinese Patent Application No. 201980056932.9, filed on August 29, 2019, with the invention title "Integrated Connector Cable".

[0002] Cross - reference to related applications This application is a continuation of U.S. Patent Application No. 16 / 551,030, filed on August 26, 2019, which claims the benefit of the filing date of U.S. Provisional Patent Application No. 62 / 725,619, filed on August 31, 2018, the disclosure of which is incorporated herein by reference. Technical field

[0003] This disclosure generally relates to optical cables and components, and specifically to reducing bending stress on such devices. Background art

[0004] In optical systems, optical cables are connected to components such as adapters, patch panels, and other optical cables configured to receive optical cables. When connectors, a housing covering the connector at the end of the cable, and the components to which the connector is connected are placed in a compact environment (e.g., a fiber optic cable termination box or unit used by telecommunications companies), the connector, the housing covering the connector at the end of the cable, and the components to which the connector is connected may be subject to bending stress. These stresses typically cause the cable or the components to which the cable is connected to fail before their intended service life. Permanent bending housings have been used to address these stresses. However, in some applications or within certain space limitations, a straight housing portion is preferred. Additionally, in certain applications, a bent cable housing may be difficult for an operator to handle.

[0005] Due to the stiffness and weight of the optical components in the cable, additional stress is added at the connection of the cable and the termination unit. For example, when the cable acts in a direction transverse to the longitudinal axis defined by the cable, it may interconnect optical fibers or interconnect optical fibers with other adapters or termination units that perform special functions, where the optical components may include filters, reflectors, and beam splitters. Such optical components occupy valuable device space and are loosely fixed.

[0006] Therefore, alternative optical cable configurations are needed to reduce bending stress in the cable and at the components to which the cable is connected, and to further improve the performance of optical cables as always. Summary of the invention

[0007] According to one aspect, an optical cable can include an optical component assembly, a first internal optical fiber, a first external optical fiber, a component cover, and a connector. The optical component assembly can include an optical unit. The first internal optical fiber and the first external optical fiber can be on opposite sides of the optical unit such that the optical unit can receive a first optical signal from the first internal optical fiber and the first external optical fiber can receive a second optical signal from the optical unit, or such that the optical unit can receive a second optical signal from the first external optical fiber and the first internal optical fiber can receive the first optical signal from the optical unit. The component cover can encapsulate the entirety of the optical unit and a first portion of the first internal optical fiber and a first portion of the first external optical fiber. The connector can include a second portion of the first external optical fiber, where the second portion is exposed to route the second optical signal.

[0008] In some arrangements, the first optical signal can be the same as the second optical signal. In some arrangements, the first optical signal can be formed by a light beam. In some such arrangements, the light beam can be modified by the optical unit and the second optical signal can be formed by the modified light beam.

[0009] In some arrangements, the optical unit can include any one or any combination of the following: a termination unit, one or more filters or filter modules (such as but not limited to optical tapping filters), a beam splitter device, a coupler device, a reflector, an attenuator, a dispersion compensator, an electro-optic element (such as but not limited to a tapping photodiode array, which can receive both an optical signal that can be transmitted by an optical fiber and an electrical signal that can be transmitted by a wire), and other optical components.

[0010] In some arrangements in which the optical unit includes a termination unit, each of the internal optical fiber and the external optical fiber can terminate at the termination unit. In some arrangements in which the optical unit includes an electro-optic component, the electro-optic component can be attached to a wire such that the electro-optic component transmits an electrical signal from the wire and can also transmit an optical signal from the first internal optical fiber or the first external optical fiber.

[0011] In some arrangements, an optical unit including an optical signal beam splitter or coupler device can enable N×M fiber coupling. The optical signal beam splitter or coupler device can be wavelength or power based. In some arrangements, the wavelength-based beam splitter or coupler device can be a wavelength division multiplexer (WDM). In some arrangements, the power-based beam splitter or coupler device (both of which are wavelength independent) can be an optical fiber tap. In some such arrangements, depending on the situation, the optical fiber tap can be parallel to the corresponding first internal optical fiber or first external optical fiber.

[0012] In some arrangements, the connector may further include a ferrule, and a second portion of the first external optical fiber may extend through the ferrule to an end of the ferrule. In some such arrangements, the connector may further include a connector housing surrounding a portion of the ferrule. In some arrangements, the connector may be a simplex connector.

[0013] In some arrangements, the cable may further include a sheath and a chamfer or a round. The sheath may surround a second portion of the first internal optical fiber. Opposite ends of the chamfer or the round may be attached to the component cover and the sheath, respectively. In some such arrangements, an outer diameter of the component cover may be greater than an outer diameter of the sheath so that the corresponding chamfer or round may taper from the component cover to the sheath. In some arrangements, the corresponding chamfer or round may be a cover that covers the sheath and is adjacent to the corresponding component cover so that the component cover is exposed. In this way, the cover may provide stress relief at an interface between the sheath and the component cover. In some arrangements, the cover may be a cover for covering an optical fiber in a form known to those skilled in the art.

[0014] In some arrangements, the cable may further include additional internal optical fibers and additional external optical fibers. The additional internal optical fibers and the additional external optical fibers may be on opposite sides of the optical unit so that the optical unit receives a third optical signal from the additional internal optical fibers and the additional external optical fibers receive a fourth optical signal from the optical unit, or so that the optical unit receives a fourth optical signal from the additional external optical fibers and the additional internal optical fibers receive a third optical signal from the optical unit. In some such arrangements, the component cover may further encapsulate corresponding first portions of the additional internal optical fibers and corresponding first portions of the additional external optical fibers. In some arrangements, the connector may include corresponding second portions of the additional external optical fibers, wherein the second portions of the additional external optical fibers may be exposed to route the fourth optical signal.

[0015] In some arrangements including additional internal optical fibers and additional external optical fibers, the connector may further include a ferrule, and second portions of the first external optical fiber and the additional external optical fibers may extend through the ferrule to an end of the ferrule. In some such arrangements, the connector may further include a connector housing surrounding a portion of the ferrule.

[0016] In some arrangements including additional internal optical fibers and additional external optical fibers, the connector may further include a connector housing, and second portions of the first external optical fiber and the additional external optical fibers may extend through the connector housing. In some such arrangements, the connector housing may be non-cylindrical. In some such arrangements, the connector housing may be cylindrical.

[0017] In some arrangements that include additional internal optical fibers and additional external optical fibers, the connector can further include a pair of ferrules, where the connector housing can surround portions of the pair of ferrules. A second portion of the first external optical fiber can extend through one of the pair of ferrules, and a second portion of the additional external optical fiber can extend through the other of the pair of ferrules.

[0018] In some arrangements that include additional internal optical fibers and additional external optical fibers, the connector can be a duplex connector, such as an LC or SC duplex connector.

[0019] In some arrangements, the cable can further include a sheath located on the first internal optical fiber and a flexible cover that attaches a component cover to the sheath. The flexible cover can be bent from a first state to a second state. The second state can be maintained in the absence of an external force applied to the optical cable. In some arrangements, the external force is non-gravitational.

[0020] In some arrangements, the cable can further include a flexible cover that attaches a component cover to the connector. The flexible cover can be bent from a first state to a second state. The second state can be maintained in the absence of an external force applied to the optical cable. In some arrangements, the external force is non-gravitational. In some such arrangements, the flexible cover can be bent up to an angle corresponding to the minimum bend radius of the optical fiber.

[0021] In some arrangements that include a flexible cover, a second portion of the first external optical fiber can extend through the flexible cover. In some arrangements that include a flexible cover, the flexible cover can be a metal tube. In some arrangements that include a flexible cover, the flexible cover and the component cover can be integrally formed with each other such that the flexible cover and the component cover are inseparable without at least one of the flexible cover and the component cover breaking. In some arrangements that include a flexible cover, it may require a greater force to bend the component cover than to bend the flexible cover. In some such arrangements, the component cover can be substantially rigid. In some arrangements that include a flexible cover, the flexible cover can be in the form of a bellows.

[0022] In some arrangements that include a flexible cover, the cable can further include a cover that covers the sheath and the component cover, where the cover can be adjacent to the flexible cover to expose the flexible cover. In this way, the sheath can provide additional stress relief in the cable. In some arrangements, the cover can be a cover that covers an optical fiber in a form known to those skilled in the art.

[0023] In some arrangements, the cable may further include a hinge that includes a pin attaching the component cover to the connector. In some such arrangements, the connector may remain in substantially the same position after bending until an external force applied to the optical cable causes the hinge to bend and thereby move the connector to a different position. In some arrangements, the external force is non-gravitational. In some arrangements, the connector and the component cover may be directly attached to the pin of the hinge to form respective portions of the hinge.

[0024] In some arrangements, the component cover or the connector may include a protrusion, and the other of the component cover or the connector may include a hole for receiving the protrusion to define a hinge attaching the component cover to the connector.

[0025] In some arrangements, the cable may further include a ball-and-socket joint. The ball-and-socket joint may include a ball attached to the component cover or the connector and a socket attached to the other of the component cover and the connector. In some such arrangements, the connector may remain in substantially the same state after bending until an external force applied to the optical cable causes the ball-and-socket joint to bend and thereby move the connector to obtain a different state. In some arrangements, the external force is non-gravitational. In some arrangements, the ball may include a ball channel, and the socket may include a socket channel. In this way, a second portion of the first optical fiber may extend through at least one of the ball channel or the socket channel.

[0026] In some arrangements, the component cover may define a cutout that may extend to an end of the cover, and a first internal optical fiber extends through the cutout. In some such arrangements, the cutout may be in the form of an inset portion of the component cover.

[0027] In some arrangements where the component cover defines a cutout, the cable may be a first cable. In such an arrangement, an additional cable in the form of the first cable may form an optical cable assembly together with the first cable. In some such arrangements, the additional cable may be bendable such that when the additional cable and the first cable are in their respective bent states, a portion of the component cover of the additional cable may be able to contact the cutout of the first cable.

[0028] In some arrangements where the component cover defines a cutout, the cable may be a first cable. In such an arrangement, an additional cable in the form of the first cable may form an optical cable assembly together with the first cable. In some such arrangements, the additional cable may be bendable such that when the additional cable and the first cable are in their respective bent states, a portion of the component cover of the additional cable may fit within the cutout of the first cable.

[0029] According to another aspect, an optical cable termination assembly can include an optical cable and a termination unit. The optical cable can include an optical component assembly, a first internal optical fiber, a first external optical fiber, a component cover, and a connector. The optical component assembly can include an optical unit. The first internal optical fiber and the first external optical fiber can be on opposite sides of the optical unit such that the optical unit can receive a first optical signal from the first internal optical fiber and the first external optical fiber can receive a second optical signal from the optical unit, or such that the optical unit can receive a second optical signal from the first external optical fiber and the first internal optical fiber can receive a first optical signal from the optical unit. The component cover can encapsulate the entirety of the optical unit and a first portion of the first internal optical fiber and a first portion of the first external optical fiber. The connector can include a second portion of the first external optical fiber, where the second portion can be exposed to route the second optical signal. The cable can be inserted into the termination unit to perform at least one of the following: route the second optical signal from the first external optical fiber to another optical cable inserted in the termination unit, or receive the second optical signal at the first external optical fiber from another optical cable inserted in the termination unit.

[0030] According to another aspect, an optical cable can include an optical component assembly, a first internal optical fiber, a first external optical fiber, a component cover, a connector, and a bendable cover. The optical component assembly can include an optical unit. The first internal optical fiber and the first external optical fiber can be on opposite sides of the optical unit such that the optical unit can receive a first optical signal from the first internal optical fiber and the first external optical fiber can receive a second optical signal from the optical unit, or such that the optical unit can receive a second optical signal from the first external optical fiber and the first internal optical fiber can receive a first optical signal from the optical unit. The component cover can encapsulate the entirety of the optical unit and a portion of the first internal optical fiber and a portion of the first external optical fiber. The connector can include a second portion of the first external optical fiber, where the second portion can be exposed to route the second optical signal. The bendable cover can attach the component cover to the connector. The bendable cover can be bent from a first state to a second state and can maintain the second state in the absence of an external force applied to the optical cable. The force required to bend the bendable cover can be less than the force required to bend the component cover. The second portion of the first external optical fiber can extend through the bendable cover. In some arrangements, the external force is non-gravitational.

[0031] In some arrangements, the first optical signal can be the same as the second optical signal. In some arrangements, the first optical signal can be formed by a light beam. In some such arrangements, the light beam can be modified by the optical unit and the second optical signal can be formed by the modified light beam.

[0032] In some arrangements, the optical unit may include any one or any combination of the following: a termination unit, one or more filters or filter modules (such as but not limited to optical tap filters), a beam splitter device, a coupler device, a reflector, an attenuator, a dispersion compensator, an electro-optic component (such as but not limited to a tap photodiode array, which may receive both optical signals that may be transmitted by an optical fiber and electrical signals that may be transmitted by an electrical wire), and other optical components.

[0033] In some arrangements in which the optical unit includes a termination unit, each of the internal optical fiber and the external optical fiber may terminate at the termination unit. In some arrangements in which the optical unit includes an electro-optic component, the electro-optic component may be attached to an electrical wire so that the electro-optic component transmits an electrical signal from the electrical wire and may also convey or transmit an optical signal from a first internal optical fiber or a first external optical fiber.

[0034] In some arrangements, an optical unit including an optical signal beam splitter or coupler device may enable N×M fiber coupling. The optical signal beam splitter or coupler device may be wavelength or power based. In some arrangements, the wavelength-based beam splitter or coupler device may be a WDM. In some arrangements, the power-based beam splitter or coupler device may be a fiber tap. In some such arrangements, depending on the circumstances, the fiber tap may be parallel to a corresponding first internal optical fiber or first external optical fiber.

[0035] In some arrangements, the connector may further include a ferrule, and a second portion of the first external optical fiber may extend through the ferrule to the end of the ferrule. In some such arrangements, the connector may further include a connector housing around a portion of the ferrule. In some arrangements, the connector may be a simplex connector.

[0036] In some arrangements, the cable may further include a sheath and a chamfered or rounded object. The sheath may surround a second portion of the first internal optical fiber. Opposite ends of the chamfered or rounded object may be attached to the component cover and the sheath, respectively. In some such arrangements, the outer diameter of the component cover may be greater than the outer diameter of the sheath so that the corresponding chamfered or rounded object may taper from the component cover to the sheath. In some arrangements, the corresponding chamfered or rounded object may be a cover that covers the sheath and is adjacent to the corresponding component cover so that the component cover is exposed. In this way, the cover may provide stress relief at the interface between the sheath and the component cover. In some arrangements, the cover may be a cover for covering an optical fiber in a form known to those skilled in the art.

[0037] In some arrangements, the cable may further include additional internal optical fibers and additional external optical fibers. The additional internal optical fibers and the additional external optical fibers may be on opposite sides of the optical unit such that the optical unit receives a third optical signal from the additional internal optical fibers and the additional external optical fibers receive a fourth optical signal from the optical unit, or such that the optical unit receives a fourth optical signal from the additional external optical fibers and the additional internal optical fibers receive a third optical signal from the optical unit. In some such arrangements, the component cover may further encapsulate corresponding first portions of the additional internal optical fibers and the additional external optical fibers. In some arrangements, the connector may include corresponding second portions of the additional external optical fibers, wherein the second portions of the additional external optical fibers may be exposed to route the fourth optical signal.

[0038] In some arrangements that include additional internal optical fibers and additional external optical fibers, the connector may further include ferrules, and the second portions of the first external optical fibers and the second portions of the additional external optical fibers may extend through the ferrules to the ends of the ferrules. In some such arrangements, the connector may further include a connector housing that surrounds a portion of the ferrules.

[0039] In some arrangements that include additional internal optical fibers and additional external optical fibers, the connector may further include a connector housing, and the second portions of the first external optical fibers and the second portions of the additional external optical fibers may extend through the connector housing. In some such arrangements, the connector housing may be non-cylindrical. In some such arrangements, the connector housing may be cylindrical.

[0040] In some arrangements that include additional internal optical fibers and additional external optical fibers, the connector may further include a pair of ferrules, wherein the connector housing may surround portions of the pair of ferrules. The second portion of the first external optical fiber may extend through one of the pair of ferrules, and the second portion of the additional external optical fiber may extend through the other of the pair of ferrules.

[0041] In some arrangements that include additional internal optical fibers and additional external optical fibers, the connector may be a duplex connector, such as an LC or SC duplex connector.

[0042] In some such arrangements, the bendable cover may be bendable up to an angle corresponding to the minimum bend radius of the optical fiber.

[0043] In some arrangements, a second portion of the first external optical fiber may extend through the flexible cover. In some arrangements, the flexible cover may be a metal tube. In some arrangements, the flexible cover and the component cover may be integrally formed with each other such that the flexible cover and the component cover are inseparable without at least one of the flexible cover and the component cover breaking. In some arrangements, it may require a greater force to bend the component cover than to bend the flexible cover. In some such arrangements, the component cover may be substantially rigid. In some arrangements, the flexible cover may be in the form of a bellows.

[0044] In some arrangements including a flexible cover, the cable may further include a shroud covering the sheath and the component cover, wherein the shroud may be adjacent to the flexible cover to expose the flexible cover. In this way, the sheath may provide additional stress relief in the cable. In some arrangements, the shroud may be a shroud covering an optical fiber in a form known to those skilled in the art.

[0045] In some arrangements, the component cover may define a cutout that may extend to an end of the cover, and the first internal optical fiber extends through the cutout. In some such arrangements, the cutout may be in the form of an inset portion of the component cover.

[0046] In some arrangements where the component cover defines a cutout, the cable may be a first cable. In such an arrangement, an additional cable in the form of the first cable may form an optical cable assembly together with the first cable. In some such arrangements, the additional cable may be flexible such that when the additional cable and the first cable are in their respective bent states, a portion of the component cover of the additional cable may be able to contact the cutout of the first cable.

[0047] In some arrangements where the component cover defines a cutout, the cable may be a first cable. In such an arrangement, an additional cable in the form of the first cable may form an optical cable assembly together with the first cable. In some such arrangements, the additional cable may be flexible such that when the additional cable and the first cable are in their respective bent states, a portion of the component cover of the additional cable may fit within the cutout of the first cable.

[0048] According to another aspect, an optical cable termination assembly may include an optical cable and a termination unit. The optical cable may include an optical component assembly, a first internal optical fiber and a first external optical fiber, a component cover, a connector, and a bendable cover. The optical component assembly may include an optical unit. The first internal optical fiber and the first external optical fiber may be on opposite sides of the optical unit such that the optical unit may receive a first optical signal from the first internal optical fiber and the first external optical fiber may receive a second optical signal from the optical unit, or such that the optical unit may receive a second optical signal from the first external optical fiber and the first internal optical fiber may receive a first optical signal from the optical unit. The component cover may encapsulate the entirety of the optical unit as well as portions of the first internal optical fiber and the first external optical fiber. The connector may include a second portion of the first external optical fiber, wherein the second portion may be exposed to route the second optical signal. The bendable cover may attach the component cover to the connector. The bendable cover may be bendable from a first state to a second state and may maintain the second state in the absence of an external force applied to the optical cable. The force required to bend the bendable cover may be less than the force required to bend the component cover. The second portion of the first external optical fiber may extend through the bendable cover. In some arrangements, the external force is non-gravitational. The optical cable may be inserted into the termination unit to perform at least one of the following: route a second optical signal from the first external optical fiber to another optical cable inserted in the termination unit, or receive a second optical signal at the first external optical fiber from another optical cable inserted in the termination unit.

[0049] According to another aspect, an optical fiber connector may include a single-fiber adapter, a multi-fiber adapter, a cover, a single optical fiber, an optical signal splitter, a multi-fiber assembly, and a mechanical transfer ferrule. The cover may include a first end and a second end and may further define a longitudinal axis. The single-fiber adapter may be coupled to the first end along the longitudinal axis. The multi-fiber adapter may be coupled to the second end along the longitudinal axis. The single optical fiber may be located within the cover along the longitudinal axis and may be at least partially received within the single-fiber adapter. The splitter may be located within the cover along the longitudinal axis and may be directly coupled to the single optical fiber. The multi-fiber assembly may be located within the cover along the longitudinal axis and may be directly coupled to the splitter. The mechanical transfer ferrule may be located within the cover along the longitudinal axis and may be directly coupled to the multi-fiber assembly and the multi-fiber adapter such that the single-fiber adapter may communicate optically with the multi-fiber adapter via the single optical fiber, the splitter, the multi-fiber assembly, and the MT ferrule.

[0050] In some arrangements, the splitter may be optically coupled to the single optical fiber and the multi-fiber assembly. In some such arrangements, the MT ferrule may be optically coupled to the multi-fiber assembly.

[0051] In some arrangements, the beam splitter can be wavelength or power based, as previously described and further described herein. In some arrangements, the wavelength-based beam splitter can be a WDM or a demultiplexer, depending on whether the optical signal routing path is through a WDM or a demultiplexer.

[0052] According to another aspect, an optical cable can include an optical fiber connector and an LC cable. The optical fiber connector can include a single-fiber adapter, a multi-fiber adapter, a cover, a single optical fiber, an optical signal beam splitter, a multi-fiber assembly, and a mechanical transfer ferrule. The cover can include a first end and a second end and can also define a longitudinal axis. The single-fiber adapter can be coupled to the first end along the longitudinal axis. The multi-fiber adapter can be coupled to the second end along the longitudinal axis. The single optical fiber can be located within the cover along the longitudinal axis and can be at least partially received within the single-fiber adapter. The beam splitter can be located within the cover along the longitudinal axis and can be directly coupled to the single optical fiber. The multi-fiber assembly can be located within the cover along the longitudinal axis and can be directly coupled to the beam splitter. A mechanical transfer (MT) ferrule can be located within the cover along the longitudinal axis and can be directly coupled to the multi-fiber assembly and the multi-fiber adapter such that the single-fiber adapter can communicate optically with the multi-fiber adapter via the single optical fiber, the beam splitter, the multi-fiber assembly, and the MT ferrule. The LC cable can be coupled to the single-fiber adapter of the optical fiber connector. The LC cable can communicate optically with the multi-fiber adapter via the single optical fiber, the beam splitter, the multi-fiber assembly, and the MT ferrule. The optical signal transmitted by the LC cable can be split into multiple optical signals and routed by the multiple optical fibers extending within the MT ferrule.

[0053] In some arrangements, the beam splitter can be wavelength or power based, as previously described and further described herein. In some arrangements, the wavelength-based beam splitter can be a WDM or a demultiplexer, depending on whether the optical signal routing path is through a WDM or a demultiplexer.

[0054] In some arrangements, the optical cable can further include a mechanical push-on (MPO) breakout adapter that can be coupled to the multi-fiber adapter of the optical fiber connector. The MPO breakout adapter communicates optically with the LC cable via the single optical fiber, the beam splitter, the multi-fiber assembly, and the MT ferrule. The multiple optical signals routed by the multiple optical fibers extending within the MT ferrule are further routed by the respective optical fibers extending within the MPO breakout adapter.

[0055] According to another aspect, an MT ferrule can include an upper cover portion, a lower cover portion that can mate with the upper cover portion, and a plurality of optical fibers. Each of the upper cover portion and the lower cover portion can be made of glass, ceramic, or another suitable material. The plurality of optical fibers can extend between the upper cover portion and the lower cover portion within an optical fiber bore defined by an optical fiber groove extending along the upper cover portion and the lower cover portion.

[0056] In some arrangements, the MT ferrule may include a plurality of alignment pins. The alignment pins may extend between the upper cover portion and the lower cover portion within pin holes defined by pin slots extending along the upper cover portion and the lower cover portion, and the alignment pins may further extend beyond the adjacent ends of the upper cover portion and the lower cover portion. BRIEF DESCRIPTION OF THE DRAWINGS

[0057] By way of example only, embodiments of the present disclosure will be described herein with reference to the accompanying drawings, in which: Figure 1 is a front view of a portion of an optical cable according to an embodiment; Figure 2A and Figure 2B and Figure 2C is a front view of a portion of an optical cable according to another embodiment; Figures 3 to 6B is a perspective view of a portion of an optical cable according to a further embodiment; Figure 7A and Figure 7B is a front view of a portion of an optical cable according to a further embodiment; Figure 8 is a plan view of an optical cable system according to another embodiment; Figure 9 is a portion of an optical cable system coupled to a patch panel device according to another embodiment Figure 8 of a plan view; Figure 10A is a perspective view of a beam splitter component integrated adapter according to another embodiment; Figure 10B is a beam splitter component integrated adapter including according to another embodiment Figure 10A of a signal separation cable exploded view; Figure 11 is Figure 10A a perspective view of the fiber optic and ferrule assembly of the beam splitter component integrated adapter shown in; Figure 12A is a perspective view of an MT ferrule and a set of optical fibers according to an embodiment; and Figure 12B is Figure 12A an exploded view of the MT ferrule and the set of optical fibers shown in. DETAILED DESCRIPTION

[0058] Referring now to the drawings, as Figure 1 shown, the cable 100 includes an inner cable portion 110, a component portion 120, and a connector portion 140. In the example shown, the cable 100 may be used to route one or more optical signals, each optical signal formed by a light beam.

[0059] The internal cable portion 110 includes an internal portion of the internal optical fiber 102 configured to route optical signals and a sheath 114 that surrounds and is substantially coaxial with the internal optical fiber. In some alternative arrangements configured to route multiple optical signals, the internal cable portion may include multiple internal portions of the internal optical fiber 102. The sheath 114 may be, but is not limited to, made of a flexible plastic material such as, but not limited to, polyvinyl chloride (PVC).

[0060] As in the example shown, the component portion 120 may include an exterior of the internal optical fiber 102, an interior of the external optical fiber 104, and an optical unit 125 that may be optically connected to the exterior portion of the internal optical fiber 102, the interior portion of the external optical fiber 104, and a component cover 127. As shown, the component cover 127 surrounds each of the exterior portion of the internal optical fiber 102, the interior portion of the external optical fiber 104, and the optical unit to provide coverage and inhibit disassembly of the optical fiber from the optical unit. The component cover 127 may be made of, but is not limited to, a plastic material, which may preferably be a moldable plastic or a metallic material such as stainless steel, which may be formed in the shape of a housing and preferably in the shape of a flexible housing. As in the example shown, the component cover 127 and the sheath 114 may interface at a circle 128, which may provide stress relief at the interface when tensioning one or both of the component cover and the sheath.

[0061] The optical unit 125 may be configured to perform any one or any combination of the following: (i) route or receive optical signals from the internal optical fiber 102; (ii) route or receive optical signals from the external optical fiber 104; (iii) route or transmit optical signals to the external optical fiber; and (iv) route or transmit optical signals to the internal optical fiber. In some arrangements, in response to the optical unit 125 receiving a first optical signal from the internal optical fiber 102 or the external optical fiber 104, the optical unit 125 may act on the first optical signal, such as filtering or amplifying the first optical signal, and then transmit a second optical signal resulting from acting on the first optical signal to the other of the internal optical fiber or the external optical fiber, respectively. In some such arrangements or in alternative arrangements, in response to the optical unit 125 receiving a first optical signal from the internal optical fiber 102 or the external optical fiber 104, the optical unit 125 may transmit the second optical signal to the other of the internal optical fiber or the external optical fiber, respectively.

[0062] The optical unit 125 may include any one or any combination of the following: a termination unit, one or more filters or filter modules (such as but not limited to optical tap filters), a beam splitter device, a coupler device, a reflector, an attenuator, a dispersion compensator, an electro-optic component (such as but not limited to a tap photodiode array, which may receive both optical signals that may be transmitted by an optical fiber and electrical signals that may be transmitted by a wire), and other optical components.

[0063] An optical unit including an optical signal beam splitter or coupler device may enable N×M fiber coupling. In this way, the internal fiber 102 may be multiple fibers that route an optical signal to a single external fiber 104 or route an optical signal from a single external fiber 104, the internal fiber may be a single fiber that routes one or more optical signals to multiple external fibers or routes one or more optical signals from multiple external fibers, or the internal fiber may be multiple fibers that route one or more optical signals to multiple external fibers or route one or more optical signals from multiple external fibers.

[0064] The optical signal beam splitter or coupler device may be wavelength or power based. In one example of a wavelength-based beam splitter or coupler device, such a device may be a wavelength division multiplexer (WDM) or other dielectric filter, which may receive a first optical signal or a second optical signal and, depending on the situation, route the corresponding first optical signal or second optical signal of a first wavelength to a corresponding first internal fiber or first external fiber, and separately route the corresponding first optical signal or second optical signal of a second wavelength different from the first wavelength to a corresponding first internal fiber or first external fiber. In one example of a power-based beam splitter or coupler device, such a device may be a fiber tap, which may divert a portion of the first optical signal or second optical signal as the other of the corresponding first optical signal or second optical signal when receiving the first optical signal or second optical signal, and transmit this diverted optical signal along the fiber tap. In some arrangements, the fiber tap may be parallel to a corresponding first internal fiber or first external fiber, depending on the situation.

[0065] An optical unit including an electro-optic component may be attached to a wire so that the electro-optic component transmits an electrical signal from the wire and may also transmit an optical signal from a first internal fiber or first external fiber. In some arrangements, the wire may be within a sheath 114 that serves as both a first internal fiber and the wire, or may extend along the outer surface of the sheath. The integrated optical unit 125 provides enhanced functionality for the cable compared to cables known in the prior art.

[0066] Still referring to Figure 1, the connector portion 140 includes: a ferrule 142 that surrounds and is substantially coaxial with an outer portion of the outer optical fiber 104; and a connector cover 144 that surrounds the ferrule and is substantially coaxial therewith. The ferrule 142 provides support for the optical fiber and aligns the end of the outer optical fiber for mating connection with a terminal or other termination unit so that optical signals can be routed through the end of the outer optical fiber in a controlled manner. In some arrangements, the connector cover 144 can be attached to the component cover 127 by: an adhesive (e.g., epoxy); a locking or other mechanical engagement between the connector cover and the component cover (such as by a dovetail, snap fit, Morse taper, or other system for directly anchoring one of these components to the other); or by using fasteners known to those skilled in the art. In other arrangements, the connector cover 144 can be integrally formed with the component cover 127 so that the connector cover and the component cover are inseparable without breaking one or both of these components.

[0067] Now referring to Figure 2A and Figure 2B , the cable 200 is the same as or substantially the same as the cable 100, except that the cable 200 includes a component cover 227 instead of the component cover 127 and further includes a flexible (i.e., bendable) cover 260. In the example shown, the component cover 227 is the same as or substantially the same as the component cover 127, except that the component cover 227 is shorter than the component cover 127, as shown by the comparison between the cable 100 and the cable 200. The component cover 227 is adjacent to the flexible cover 260 rather than to the connector cover 144. In alternative arrangements, the component covers in the form of the component covers 127 and 227 can have longer or shorter lengths, or even the same length relative to each other. In some arrangements, the flexible cover 260 can be attached to the component cover 127 by: an adhesive (e.g., epoxy); a locking or other mechanical engagement between the connector cover and the component cover (such as by a dovetail, snap fit, Morse taper, or other system for directly anchoring one of these components to the other); or by using fasteners known to those skilled in the art. In other arrangements, the flexible cover 260 can be integrally formed with the component cover 227 so that the flexible cover and the component cover are inseparable without breaking one or both of these components. In some arrangements, the flexible cover 260 can be attached to the connector cover 144 by an adhesive (e.g., epoxy) or fasteners known to those skilled in the art. In other arrangements, the flexible cover 260 can be integrally formed with the connector cover 144 so that the flexible cover and the component cover are inseparable without breaking one or both of these components.

[0068] As Figure 2BAs shown, the flexible cover 260 may include a bellows 265 that can expand, contract, and bend to provide flexibility to the flexible cover. As in the example shown, the bellows 265 may be rigid enough so that the bellows maintains a bent or straight state until the cable 200 is subjected to an external force sufficient to change the bent or straight state of the bellows. As used herein, an "external force" is a force applied to a structure that is not a force between the internal components of the structure (i.e., an "internal force"). In this way, gravity or human contact acting on the structure is considered an external force in the context of the present disclosure. When the bellows 265 is in a bent state as shown in Figure 2B as shown, more of the component portion 220 is closer to the connector portion 140 than when the bellows is in a straight state as shown in Figure 2A as shown. In this way, when the bellows is in a bent state, an external force applied to any of the internal cable portion 110, the component portion 220, and the internal portion of the bellows 265 between the component portion 220 and the bend in the bellows will apply a torque to the connector 140 that is less than the torque applied to the connector portion by the same external force applied at the same location along the cable 200 when the bellows 265 is in a straight state and thus the cable 200 is in a straight state. Thus, the cable 200 limits the torsional stress on the cable 200 and its attached components while providing a compressible cable for assembly into a tighter space as needed.

[0069] The flexible cover 260 may be in the form of a bendable metal tube. A variety of metals may be used for this application, including but not limited to stainless steel, copper, and nickel, as well as alloys and combinations of these metals. In this way, the flexible cover 260 may be in the form of a shaft for supporting a table lamp or a shaft for an endoscope tube. Other materials such as structured plastics in the form of bellows, for example, may also be used. The flexible cover 260 may be prepared to have a preset length. In this way, the flexible cover 260 can be bent at most to an angle corresponding to the minimum bending radius of the external optical fiber 104, and preferably to an angle corresponding to a radius slightly larger than the minimum bending radius of the external optical fiber.

[0070] In an alternative arrangement of the cable 200, the cover 260 may not be flexible but may be permanently bent at a preset angle such that bending the cover by any large amount, for example, bending it to an angle 5%-20% greater than the preset angle, may cause the cover to rupture. The rigidity of such a cable arrangement can provide additional protection for the optical unit 125 that can be incorporated into the cable and can avoid partial straightening after the cover is bent due to elasticity that may occur in some arrangements of the flexible cover 260.

[0071] As is known to those skilled in the art, the arrangement of the flexible cover 260 can be used with a permanently bent shroud that can be placed above the interface of the flexible cover 260 and the component cover 227, above the component cover 227, above the interface of the component cover 227 and the internal cable portion 110, or the arrangement of the flexible cover 260 as is known to those skilled in the art can be used with a straight shroud that is placed above the component cover 227 and the interface of the component cover 227 and the internal cable portion 110. As Figure 2C shown, where the cable 200A is inserted into the socket of a termination unit 99 (e.g., a device, a patch panel, an adapter), as is known to those skilled in the art, the arrangement of a permanently bent cover or the flexible cover 260 can be used with a straight shroud 250 that can be flexible. As further shown, the shroud 250 can be placed at the interface of the component cover 227 and the internal cable portion 110.

[0072] In some alternative arrangements, one or both of the plurality of internal optical fibers 102 and the plurality of external optical fibers 104 can extend through a component cover, such as the component covers 127, 227. In such an arrangement, the optical unit 125 can be configured to perform any one or any combination of the following: (i) route or receive corresponding optical signals from any one or any combination of the plurality of internal optical fibers 102; (ii) route or receive corresponding optical signals from any one or any combination of the plurality of external optical fibers 104; (iii) route or transmit the corresponding optical signals to the plurality of external optical fibers; and (iv) route or transmit the corresponding optical signals to the plurality of internal optical fibers.

[0073] Reference Figure 3 , the cable 300 is a duplex connector that is the same as or substantially the same as the cable 200, except that the cable 300 includes dual ferrules 342A, 342B in place of the single ferrule 142, and a component cover 327 and a connector cover 344 that are larger than the corresponding components of the cable 200. Each of the dual ferrules 342A, 342B surrounds and is substantially coaxial with the outside of the plurality of external optical fibers 104, and is further surrounded by the connector cover 344. Each of the dual ferrules 342A, 342B provides support for the corresponding external optical fiber 104 and aligns the end of the corresponding external optical fiber for mating connection with a terminal or other termination unit so that optical signals can be routed through the end of the external optical fiber in a controlled manner. In the Figure 4 shown alternative arrangement, the cable 400 is an LC duplex connector that is the same as or substantially the same as the cable 300, except that the cable 400 includes a clip for snap connection that is known to those skilled in the art for LC connectors.

[0074] Now reference Figure 5A and Figure 5B, the cable 500 is a multi-fiber push-on (MPO) connector and is a significant enhancement to MPO connectors such as the MTP® of US Conec Ltd. The cable 500 is the same as or substantially the same as the cable 200, except that the cable 500 includes a multi-hole ferrule 542 in place of the single-hole ferrule 142, and component caps 527 and connector caps 544 that are larger than the corresponding components of the cable 200. The outer portions of the plurality of outer optical fibers 104 are substantially coaxial with and surrounded by the corresponding holes of the ferrule 542. The ferrule 542 is surrounded by the connector cap 544. In some arrangements, the connector cap 544 can serve as a housing that includes a connector body surrounding the ferrule, a slidable cap surrounding the connector body, and a locking portion for engaging a mating locking portion (e.g., a hook) of an adapter or other termination unit to couple the housing and thus the cable to the termination unit, as is known to those skilled in the art. As shown in the example of Figure 5B , the connector cap 544 defines the end of the hole of the ferrule 542. The ferrule 542 provides support for each outer optical fiber 104 and aligns the end of each outer optical fiber for mating connection with a terminal or other termination unit so that optical signals can be routed through the end of each outer optical fiber in a controlled manner.

[0075] As Figure 5A and Figure 5B further shown, the cable 500 also includes alignment pins 543A, 543B extending from the exposed end of the connector cap 544. As shown, the alignment pins 543A, 543B are preferably located on opposite sides of the ferrule 542, but in other arrangements, the alignment pins can extend from other locations on the connector cap, including from other locations on the exposed end of the connector cap, or even from one or more sides of the connector cap. At least a portion of any such alignment pin can extend in a direction such that the ferrule 542 and thus the optical fibers extending therein extend in that direction so that an alignment member can be received in the housing of a terminal or other termination unit to maintain the stability of the connection between the cable 500 and such terminal or other terminal unit.

[0076] Now referring to Figure 6A, cable 600 is the same as or substantially the same as cable 200, except that cable 600 includes a component portion 620 that replaces component portion 220, a connector portion 640 that replaces connector portion 140, and at least one hinge pin 660 that replaces flexible cover 260. Component portion 620 is the same as or substantially the same as component portion 220, except that component portion 620 further includes parallel arms 631A, 631B extending from component cover body 621. Connector portion 640 is the same as or substantially the same as connector portion 140, except that connector portion 640 further includes an arm 651 extending from connector cover body 641. As shown, arm 651 can be configured to fit between parallel arms 631A, 631B, and in an alternative arrangement, this configuration can be reversed so that the arm extending from the component cover body can be configured to fit between the parallel arms extending from the connector cover body, such as in Figure 6B the example of cable 600' shown, or the configuration can be changed so that the parallel arms of the connector portion alternate with the parallel arms of the component portion. A single hinge pin 660 extends through the holes defined by each of arms 631A, 631B, 651, or in other arrangements, a hinge pin extends through the holes in only arms 631A, 651 and another hinge pin extends through the holes in only arms 631B, 651. In this way, connector portion 640 can rotate relative to component portion 620 to bend cable 600. In some arrangements in the form of cable 600, the hinge pin can be integrally formed with connector portion 640 so that the hinge pin is a protrusion extending from the connector portion, and in arrangements in the form of cable 600', the hinge pin can be integrally formed with the component cover body so that the hinge pin is a protrusion extending from the component cover body.

[0077] Similar to component portion 220, component portion 620 surrounds optical unit 125 and includes a channel through which a portion of internal optical fiber 102 and a portion of external optical fiber 104 extend. Similar to connector portion 240, connector portion 640 includes a channel through which a portion of external optical fiber 104 extends. External optical fiber 104 can extend between double hinge pins 660 inserted into respective arms 631A, 631B, 651, or can extend around a single hinge pin 660 inserted into all three arms.

[0078] In some arrangements, an inner arm (e.g., arm 651) can be extended such that it is compressed by outer arms (e.g., arms 651A, 651B). This compression can be sufficient so that an external force applied to the cable 600 is required to bend the connector portion 640 relative to the component portion 620 from an initial state to a different bent state or a straight state. In some arrangements, at least one hinge pin 660 can be press-fit inserted into at least one of the arms 631A, 631B of the component portion 620 and also press-fit inserted into the arm 651 of the connector portion 640. In this way, rotation of the component portion 620 relative to the connector portion 640 can be inhibited such that an external force applied to the cable 600 is required to bend the connector portion 640 relative to the component portion 620 from an initial state to a different bent state or a straight state. In yet another arrangement, the component portion 620 can be attached to the connector portion 640 to create a ratcheting effect, whereby the connector portion 640 rotates in a single direction to a bent state and does not rotate in the opposite direction until a release button on the component portion or the connector portion is pressed to allow the passage of teeth on the other of the component portion or the connector portion to bypass a lever or step attached to or engaged with the release button. This configuration can be used to prevent any rotation or at least any significant rotation of the component portion 620 relative to the connector portion 640 until the release button is pressed.

[0079] When the cable 600 is in the bent state as shown in FIG. 5, more portions of the component portion 620 are closer to the connector portion 640 than when the cable 600 is in the straight state. In this way, an external force applied to the inner cable portion 110 or the component portion 620 when the cable 600 is in the bent state will apply a torque to the connector portion 640 that is less than the torque applied to the connector portion by the same external force applied at the same location along the cable 600 when the cable 600 is in the straight state. Thus, the cable 600 limits the torsional stress on the cable 600 while providing a compressible cable for fitting into tighter spaces as needed.

[0080] Now refer to Figure 7A, cable 700 is the same as or substantially the same as cable 600, except that cable 700 includes a component portion 720 in place of component portion 620, a connector portion 740 in place of connector portion 640, and does not include hinge pin 660. Component portion 720 is the same as or substantially the same as component portion 620, except that component portion 720 includes a lip 731 extending from component cover body 721 for defining a socket in place of parallel arms 631A, 631B extending from component cover body 621. Connector portion 740 is the same as or substantially the same as connector portion 640, except that connector portion 740 includes a ball portion 751 extending from connector cover body 741 in place of parallel arms 651A, 651B extending from connector cover body 641. As shown, ball portion 751 can be configured to fit within the socket defined by lip 731 and component cover body 721, and in an alternative arrangement, this configuration can be reversed such that the lip can extend from the connector cover body and the ball portion can extend from the component cover body, such as in the example of cable 700' shown in Figure 7B . Thus, the ball portion and the socket define a ball-and-socket joint, and connector portion 740 can rotate relative to component portion 720 to bend cable 700. Similar to component portion 620, component portion 720 surrounds optical unit 125 and includes a channel 753 through which a portion of inner optical fiber 102 and a portion of outer optical fiber 104 extend. Similar to connector portion 640, connector portion 740 includes a channel 754 through which a portion of outer optical fiber 104 extends.

[0081] In some arrangements, ball portion 751 can be press-fit into the socket defined by lip 731 and cover body 721. In this way, rotation of component portion 720 relative to connector portion 740 can be inhibited, such that an external force applied to cable 700 is required to bend connector portion 740 relative to component portion 720 from an initial state to a different bent state or a straight state.

[0082] When cable 700 is in the bent state as shown in Figure 7A , more portions of component portion 720 are closer to connector portion 740 compared to when cable 700 is in a straight state. In this way, an external force applied to inner cable portion 110 or component portion 720 when cable 700 is in a bent state will apply a torque to connector portion 740 that is less than the torque applied to connector portion 740 by the same external force applied at the same position along cable 700 when cable 700 is in a straight state. Thus, cable 700 limits torsional stress on cable 700 while providing a compressible cable to fit into a tighter space as needed.

[0083] Now refer to Figure 8, each cable 800 is the same as or substantially the same as cable 200, except that each cable 800 includes a component cover 827 of component portion 820 in place of component cover 227 of component portion 220. Component cover 827 is the same as component cover 227, except that component cover 827 includes a notch 829 that defines at least one longitudinal edge of the component cover. As Figure 8 shown, when both cables are in a bent state, a first cable 800 can be placed adjacent to an additional cable 800 such that a portion of the first cable fits within the notch 829 of the additional cable. In this manner, as further shown, the first cable 800 can be bent and placed adjacent to the bent additional cable 800 such that a longitudinal edge of the first cable opposite the notch 829 of the first cable follows the longitudinal edge of the additional cable 800.

[0084] As Figure 9 shown, cable 800 can be operatively coupled to an attachment member 882 of a patch panel device, where certain cables can be operatively coupled to a movable member 896 of the attachment member, allowing such cables to be moved away from other cables to facilitate easier plugging and unplugging of the cables, as more fully described in U.S. Patent Nos. 8,939,792 B2; 9,851,523 B2; and U.S. Patent Application No. 15 / 917,965, the disclosures of which are incorporated herein by reference in their entirety. Due to notch 829, and further in view of movable member 896, cable 800 can be inserted into respective ports attached to attachment member 882 even when the cable is in a bent state.

[0085] Now refer to Figure 10A and Figure 10B, the beam splitter component integrated adapter 905 includes an LC adapter 910, a single-fiber component 920 having a first end that mates with the inner end of the LC adapter, a beam splitter 930 having a first end that mates with the single-fiber end of the single-fiber component, a multi-fiber ribbon component 940 having a closed end that mates with the multi-fiber end of the beam splitter, a mechanical transfer (MT) ferrule 950 having an inner end that mates with the open end of the multi-fiber ribbon component 940, and a mechanical push-on (MPO) adapter 960 having an inner end that houses the outer end of the MT ferrule. As shown, an LC input cable 970 can be inserted into the outer end of the LC adapter 910 that is opposite the inner end of the LC adapter to form an input cable with a connector that is the outer end of the MPO adapter 960 that is opposite the inner end of the MPO adapter. As further shown, an MPO branch cable 980 can be inserted into the outer end of the MPO adapter 960 to form an output cable. The LC input cable 970 and the MPO branch cable 980 can be inserted into the outer end of the integrated adapter 905 to form a signal separation cable 900. In this way, the integrated adapter 905 is used to convert an optical signal (e.g., an optical input) of a single fiber along the LC input cable 970 into multiple optical signals, such as multiple parallel optical outputs transmitted by the branch cable 980 and formed by separating the optical signal transmitted by the LC input cable. The signal separation cable 900 can be used, for example, to make passive optical network (PON) architecture connections. In some arrangements, PON connections can be used to evenly distribute power from a central location to individual locations. For example, power from a service provider distributed in a city or town can be separated and evenly distributed to individual homes within the city or town. In some other arrangements, PON connections can allow uneven power distribution. For example, it allows tapping of signals to monitor signal quality. In some such arrangements, the power can be distributed very unevenly. For example, only 5% of the power can be tapped while the remaining power continues along the same route.

[0086] In the example shown, the LC input cable 970, LC adapter 910, beam splitter 930, MPO adapter 960, and MPO branch cable 980 are off-the-shelf components known to those skilled in the art, while the single fiber assembly 920 and multi-fiber ribbon assembly 940 are custom made. Examples of other suitable single fiber assemblies, beam splitters, and multi-fiber ribbon assemblies for use with the signal splitter cable 900 are shown and described in http: / / www.fiber-optic-tutorial.com / typical-example-of-photonic-packaging.html#more-498 and http: / / www.satellitebyfibre.co.uk / contents / en-uk / d111.html, the disclosures of which are incorporated herein by reference. Figure 10A and Figure 10B The MT ferrule 950 shown in FIG. 1 is an off-the-shelf plastic component known to those skilled in the art, but in some arrangements, may be replaced with a plastic component as further discussed herein. Figure 12A and Figure 12B The glass or silicon MT ferrule shown in FIG. 5 is replaced by the glass or silicon MT ferrule shown in FIG. 5 , and in some other arrangements may be made of ceramic or metal.

[0087] like Figure 11 As shown, the single fiber assembly 920 includes a single optical fiber extending through a ferrule 922, wherein the optical fiber is received in a Figure 10B 923, and the ferrule is received in the LC adapter 910. The fiber ferrule 923 is preferably made of an inorganic material having the same thermal expansion as the beam splitter 930. Such materials may be, but are not limited to, glass, ceramic, or metal so that the fiber ferrule can withstand high temperatures during the manufacture of the integrated adapter 905. As in the example shown, the fiber ferrule 923 may be in the form of a rectangular prism that serves as a ferrule for the optical fiber 921 to align the optical fiber with the single fiber end of the single fiber assembly of the beam splitter 930. In some alternative arrangements, the single fiber ferrule may be in the form of a two-part multi-fiber ribbon assembly 940, except that the single fiber ferrule may include only a single groove formed by opposing cover portions, as further discussed herein with respect to the multi-fiber ribbon assembly.

[0088] like Figure 10BFurther shown, the beam splitter 930 includes a branching network 932 of optical fibers, which is enclosed by a housing 934 and held in the same position relative to each other. As in the example shown, the beam splitter 930 can be a planar optical waveguide circuit (PLC), where the housing 934 can preferably be made of fused silica or other glass materials with relatively high heat resistance. The end of the single optical fiber 921 is aligned with the end of the single optical fiber on one end of the optical fiber network 932 so that the single optical fiber in the optical fiber network receives the optical signal transmitted by the optical fiber 921. In this way, the optical signal is split by the beam splitter 930 into multiple optical signals.

[0089] The multi-fiber ribbon assembly 940 includes an upper cover portion 942, a lower cover portion 944, and optical fibers 956 aligned with opposing grooves in the upper and lower cover portions, which can preferably be in the form of V-grooves such that when the upper and lower cover portions are assembled together, the optical fibers are compressed between the grooves in the upper cover portion and the grooves in the lower cover portion. This configuration is similar to Figure 12A and Figure 12B the configuration of the MT ferrule 1050 shown in. The exposed ends of the optical fibers 956 at the closed end of the multi-fiber ribbon assembly 940 are aligned with the multi-fiber ends of the beam splitter 930 so that the optical signals routed by the exposed ends of the optical fibers at the multi-fiber ends of the beam splitter are received by the bare ends of the optical fibers at the closed end of the multi-fiber ribbon assembly.

[0090] The portions of the jacket covering each optical fiber 956 are removed from each optical fiber to form jacketless portions of the optical fibers at the closed end of the multi-fiber ribbon assembly 940 (see Figure 12BA similar example of the unjacketed portion at the opposite end of the optical fiber 956 at the closed end of the MT ferrule 1050 as shown. The jacketed portion of the optical fiber 956 is inserted into the inner end of the MT ferrule 950 within the corresponding port of the MT ferrule. The outer (male) end of the MT ferrule 950 is inserted into the inner (female) end of the MPO adapter 960. The MT ferrule 950 and the MPO adapter 960 are configured such that when the MT ferrule 950 is received within the MPO adapter 960 and the MPO breakout cable 980 is received within the MPO adapter, the unjacketed ends of the optical fibers 956 within the MT ferrule are aligned with the ends of the corresponding optical fibers within the breakout connector 981 of the MPO breakout cable. Alignment pins (not shown) on the breakout connector 981 can be permanently attached to and extend from the MT ferrule within the housing of the breakout connector, and when the MT ferrule 950 and the MPO breakout cable 980 are inserted into the MPO adapter 960, enter the alignment holes 958A, 958B of the MT ferrule 950 to assist in aligning the optical fibers 956 within the MT ferrule 950 with the optical fibers within the MT ferrule of the breakout connector. In this way, the optical signals routed by the optical fibers 956 extending within the MT ferrule 950 are received by the corresponding optical fibers within the MPO breakout cable 980. In an alternative arrangement, the alignment pins can be permanently attached to and extend from the housing of the MT ferrule, and when the MT ferrule and the MPO breakout cable are inserted into the MPO adapter, are received within the corresponding alignment holes of the breakout connector to assist in aligning the optical fibers within the MT ferrule with the optical fibers within the breakout connector.

[0091] As Figure 10A and Figure 10B Further shown, the single-fiber assembly 920 mates with the beam splitter 930 through an adhesive 906 to maintain alignment of the end of the optical fiber 921 at the second end of the single-fiber assembly with the end of the optical fiber at the single-fiber end of the beam splitter, and the beam splitter mates with the multi-fiber ribbon assembly 940 through an adhesive 907 to maintain alignment of the end of the optical fiber at the multi-fiber end of the beam splitter with the end of the corresponding optical fiber 956 at the closed end of the multi-fiber ribbon assembly. Additionally, an adhesive 908 is applied at the interface of the open end and the closed end of the multi-fiber ribbon assembly 940. In this way, the adhesive 908 fixes the optical fiber 956 in the groove of the lower cover portion 944 of the multi-fiber ribbon assembly 940. Each of the adhesives 906, 907, and 908 can be, but is not limited to, an epoxy resin.

[0092] Now refer to Figure 12A and Figure 12B, the MT ferrule 1050 can be used to replace the MT ferrule 950. The MT ferrule 1050 includes an upper cover portion 1052 and a lower cover portion 1054. As shown, the optical fibers 956 of the multi-fiber ribbon cable 955 can be inserted into the opposing cable grooves 1053, 1055 of the upper cover portion 1052 and the lower cover portion 1054 and aligned therealong such that when the upper cover portion and the lower cover portion are assembled together, the unjacketed portion 956A of the optical fiber is compressed between the cable grooves. As further shown, the upper cover portion 1052 extends only over a portion of the lower cover portion 1054.

[0093] To fabricate the MT ferrule 1050, the unjacketed portion 956A of the optical fiber 956 can be inserted into the cable groove 1055. A temporary adhesive (e.g., an adhesive of relatively high viscosity) or a mechanical clamp can be applied to the unjacketed portion 956A of the optical fiber 956 extending along the cable groove 1055 and, in some arrangements, to the jacketed portion of the optical fiber 956 extending along the cable groove 1055 to maintain the position of the unjacketed portion relative to the cable groove 1055 of the lower cover portion 154. Then, the upper cover portion 1052 and the lower cover portion 1054 are joined by an adhesive (e.g., epoxy) or by a low-temperature solder, Figure 12AIn the form shown, the unjacketed portions 956A between the cable grooves 1053, 1055 cooperate with each other and are allowed to cure. Then, relative to an arrangement in which the cable grooves 1053, 1055 are compressed onto the unjacketed portion 956A of the optical fiber only between the optical fiber and the MT ferrule 1050, a permanent adhesive is applied to the jacketed portion of the optical fiber 956 to reduce the chance of any optical fiber breakage if the optical fiber is bent. The upper cover portion 1052 and the lower cover portion 1054 may preferably be made of glass (e.g., fused silica) or silicon, which provides sufficient heat resistance to maintain the cover portions in a solid state under the heat treatment during the manufacture of the integrated adapter 905. The double alignment pins 1057A, 1057B are placed within the respective lower pin grooves 1058A, 1058B, and when the upper cover portion 1052 is disposed on and mates with the lower cover portion 1054, the double alignment pins 1057A, 1057B extend through the upper pin grooves 1059A, 1059B and are maintained in place thereby. When the MT ferrule 1050 is fully assembled with the double alignment pins 1057A, 1057B disposed appropriately between the upper cover portion 1052 and the lower cover portion 1054, the alignment pins extend beyond the ends of the upper cover portion and the lower cover portion. In this way, when the MT ferrule 1050 and the branch cable are inserted into the MPO adapter 960, the alignment pins 1057A, 1057B can be inserted into the respective alignment holes of the respective branch connectors of the branch cable to assist in fully aligning the ends of the optical fibers 956 within the branch connectors with the ends of the respective optical fibers of the MPO branch cable. Such a branch cable having such a branch connector may be in the form of an MPO branch cable 980, except that the branch connector may include alignment holes and does not include the alignment pins described previously herein with respect to the branch cable 980. In an alternative arrangement, the branch cable 980 may be employed, and the pins of the branch cable may extend into holes defined by the respective interfaces of the lower pin grooves 1058A, 1058B and the upper pin grooves 1059A, 1059B.

[0094] In one example, to assemble the components of a beam splitter component integrated adapter (such as integrated adapter 905 but using MT ferrule 1050), before curing adhesives 906, 907, 908, fixtures are used to axially align the components of the branch adapter with each other to mate with the corresponding branch adapter components. Then, preferably, the aligned components of the branch adapter are heated to a temperature at which the low-temperature solder can flow to cure adhesives 906, 907, 908 simultaneously. Then, connector cover 990 is placed around the mating components of the branch adapter (the connector cover 990 can be in the form of the rectangular box, sheath, encapsulation, or other known cover shown that is suitable for providing a watertight seal for the components within the cover) so that the inner ends of LC adapter 910 and MPO adapter 960 are received within the corresponding ends of the cover. In this way, connector cover 990 provides mechanical support that generally aligns beam splitter 930 and adapters 910, 960. Connector cover 990 can be made of a plastic material sufficient to inhibit dust intrusion into integrated adapter 905. MT ferrule 1050 uses glass, ceramic, or other suitable material that allows the MT ferrule to be heated along with adhesives 906, 907, 908, thus providing a faster assembly operation for the branch adapter. In this way, at least any combination of single-fiber component 920, adhesive 906, beam splitter 930, adhesive 907, multi-fiber ribbon component 940, adhesive 908, and multiple optical fibers 956 can be heat-treated and then cooled simultaneously such that the heated and cooled components are mated together as an assembly.

[0095] It should be further understood that, whether or not specifically disclosed herein, the disclosure described herein includes any possible combination of the above specific features. For example, where a specific feature is disclosed in the context of a particular aspect, arrangement, configuration, or embodiment, that feature can also be used and / or used in the context of that technology and generally the other particular aspects, arrangements, configurations, or embodiments of that technology to the extent possible.

[0096] In addition, although the technology herein has been described with reference to specific features, it should be understood that these features are only illustrative of the principles and applications of the technology. Accordingly, it should be understood that various modifications can be made to the illustrative embodiments set forth above, including changes in the dimensions of the various features described herein, and other arrangements can be designed without departing from the spirit and scope of the technology. In this regard, the technology encompasses many additional features in addition to those specific features set forth herein. Moreover, since the invention is defined by the appended claims, the above disclosure should be taken in an illustrative rather than a limiting sense.

Claims

1. An optical cable, the optical cable comprising: an optical component assembly, the optical component assembly including an optical unit; a first internal optical fiber and a first external optical fiber, the first internal optical fiber and the first external optical fiber being on opposite sides of the optical unit such that the optical unit receives a first optical signal from the first internal optical fiber and the first external optical fiber receives a second optical signal from the optical unit, or such that the optical unit receives the second optical signal from the first external optical fiber and the first internal optical fiber receives the first optical signal from the optical unit; a component cover that encapsulates the entirety of the optical unit and a first portion of the first internal optical fiber and a first portion of the first external optical fiber; and a connector that includes a second portion of the first external optical fiber, the second portion being exposed to route the second optical signal.

2. The cable according to claim 1, wherein, The optical unit is a termination unit, and each of the internal optical fiber and the external optical fiber terminates at the termination unit.

3. The cable according to claim 1, wherein, The optical unit is at least one selected from the following: a termination unit, a wavelength division multiplexer (WDM), a tap filter, a reflector, an attenuator, and a dispersion compensator.

4. An optical cable assembly, the optical cable assembly comprising: the cable according to claim 1, the cable being a first cable, wherein the component cover defines a cutout extending to an end of the cover, and the first internal optical fiber extends through the cutout; and an additional cable in the form of the first cable, wherein the additional cable is bendable such that when the additional cable and the first cable are in their respective bent states, a portion of the component cover of the additional cable is able to contact the cutout of the first cable.

5. An optical cable assembly, the optical cable assembly comprising: the cable according to claim 1, the cable being a first cable, wherein the component cover defines a cutout extending to an end of the cover, and the first internal optical fiber extends through the cutout; and an additional cable in the form of the first cable, wherein the additional cable is bendable such that when the additional cable and the first cable are in their respective bent states, a portion of the component cover of the additional cable fits within the cutout of the first cable.

6. An optical cable termination assembly, the optical cable termination assembly comprising: the cable according to claim 1; and a termination unit into which the cable is inserted to perform at least one of the following: route the second optical signal from the first external optical fiber to another optical cable inserted in the termination unit, or receive the second optical signal from another optical cable inserted in the termination unit at the first external optical fiber.

7. An optical cable, the optical cable comprising: an optical component assembly, the optical component assembly including an optical unit; A first internal optical fiber and a first external optical fiber, the first internal optical fiber and the first external optical fiber being on opposite sides of the optical unit such that the optical unit receives a first optical signal from the first internal optical fiber and the first external optical fiber receives a second optical signal from the optical unit, or such that the optical unit receives the second optical signal from the first external optical fiber and the first internal optical fiber receives the first optical signal from the optical unit; A component cover that encapsulates the entirety of the optical unit and portions of the first internal optical fiber and the first external optical fiber; A connector that includes a second portion of the first external optical fiber, the second portion being exposed to route the second optical signal; And A flexible cover that attaches the component cover to the connector, wherein the flexible cover is bendable from a first state to a second state and maintains the second state in the absence of an external force applied to the optical cable; wherein the force required to bend the flexible cover is less than the force required to bend the component cover, and wherein the second portion of the first external optical fiber extends through the flexible cover.

8. An optical fiber connector, the optical fiber connector comprising: A single-fiber adapter; A multi-fiber adapter; A cover that includes a first end and a second end and defines a longitudinal axis, wherein the single-fiber adapter is coupled to the first end along the longitudinal axis and the multi-fiber adapter is coupled to the second end along the longitudinal axis; A single optical fiber that is located within the cover along the longitudinal axis and is at least partially received within the single-fiber adapter; A beam splitter that is located within the cover along the longitudinal axis and is directly coupled to the single optical fiber; A multi-fiber assembly that is located within the cover along the longitudinal axis and is directly coupled to the beam splitter; and A mechanical transfer (MT) ferrule that is located within the cover along the longitudinal axis and is directly coupled to the multi-fiber assembly and the multi-fiber adapter such that the single-fiber adapter communicates optically with the multi-fiber adapter via the single optical fiber, the beam splitter, the multi-fiber assembly, and the MT ferrule.

9. An optical cable, the optical cable comprising: The optical fiber connector according to claim 8; And An LC cable that is coupled to the single-fiber adapter of the optical fiber connector, wherein the LC cable communicates optically with the multi-fiber adapter via the single optical fiber, the beam splitter, the multi-fiber assembly, and the MT ferrule, and wherein an optical signal transmitted by the LC cable is split into multiple optical signals and routed by a plurality of optical fibers extending within the MT ferrule.

10. A mechanical transfer (MT) ferrule, the mechanical transfer ferrule comprising: An upper cover portion made of a material selected from the group consisting of glass and silicon; A lower cover portion that mates with the upper cover portion and is made of a material selected from the group consisting of glass and silicon; And A plurality of optical fibers, the plurality of optical fibers extending between the upper cover portion and the lower cover portion within an optical fiber hole defined by an optical fiber groove extending along the upper cover portion and the lower cover portion.

Images