Nesting shoe for double-row termination sleeve tape for one-dimensional photonic chip beach front and method

Abstract

Interleaving shoe (102) for a multi-fiber arrangement, the interleaving shoe (102) comprising: a body having a first end adapted for insertion over the multi-fiber assembly and a second end opposite the first end, the second end having an opening, the body being tapered in a first direction between the first end and the second end; and a guide structure (206) disposed within the body, the guide structure (206) being configured to receive optical fibers (104, 202) from both rows of a dual-row termination sleeve (100), the guide structure (206) comprising a plurality of channels (204), each channel (204) being configured to receive a single optical fiber (104, 202), each channel (204) having a first end and a second end, the second end being offset from the first end in a second direction perpendicular to the first direction, and the first ends of the channels (204) being arranged in vertically stacked rows, the vertically stacked rows being arranged at the first ends of the channels (204) without offset along the second direction.

Description

BACKGROUND

[0001] The present invention generally relates to the use of ribbons and multi-port (MT) termination ferrules in fiber optic connections. More specifically, the present invention relates to an interlacing boot for a two-row fiber array emerging from a termination ferrule for a one-dimensional (1D) photonic chip beachfront.

[0002] Fiber optic assemblies or fiber optic ribbons (sometimes referred to herein simply as "ribbons" for convenience) are supplied with multiple individual optical fibers arranged parallel to one another. Each individual optical fiber has a glass core and a glass cladding, both protected within a polymer sheath, which may be color-coded. A plurality of these individual optical fibers are embedded in a polymer ribbon matrix to form a fiber optic ribbon. Fiber optic ribbons are commonly supplied as 2-fiber ribbons, 4-fiber ribbons, 8-fiber ribbons, 12-fiber ribbons, and 16-fiber ribbons. An array of fiber optics may contain multiple optical fibers arranged parallel to one another and may contain fibers of / in various types, sequences, and combinations.

[0003] Fiber optic connectors typically use a termination sleeve into which the optical fibers are terminated and secured. The multi-terminal (MT) termination sleeve is one such termination sleeve commonly used in fiber optic applications where a fiber optic ribbon or array terminates in the termination sleeve connector. The MT termination sleeve is ubiquitous because it can accommodate various numbers of optical fibers and fiber ribbons. For example, an MT-24 termination sleeve can accommodate up to 24 optical fibers, while an MT-8 termination sleeve only serves eight fibers. Typically, the optical fibers are stacked in an array of one, two, or four rows; for example, in the case of an MT-24 termination sleeve, there is an array of two rows of 12 fibers, or equivalently, twelve columns of two fibers.

[0004] The document US 5,367,595 A describes a fiber optic connector which connects a fiber optic harness with a plurality of jacketed optical fibers to an optical device having a flat rectangular contact surface. SUMMARY

[0005] The invention is described by the features of the independent claims. Embodiments are specified in the dependent claims.

[0006] Embodiments of the invention relate to an interleaving shoe for optical fibers. One non-limiting example of the interleaving shoe includes a body having a first end configured to pass over a termination sleeve having multiple rows of fiber assemblies, and a second end opposite the first end. The second end includes an opening. The body is tapered in a first direction between the first end and the second end. The interleaving shoe further includes guide structures disposed within the body. The guide structures include one or more channels, each channel configured to receive a single optical fiber. Each channel has a first end and a second end, and the second end is offset from the first end in a second direction perpendicular to the first direction.

[0007] Embodiments of the invention relate to a method of using an interleaving shoe to automatically interleave optical fibers from a two-row fiber array. A non-limiting example of the method includes inserting the optical fibers into a first end of an interleaving shoe in a first direction. The interleaving shoe may include guide structures having one or more channels. Each channel may be configured to receive a single optical fiber. Each channel may have a first end and a second end, and the second end may be offset from the first end in a second direction perpendicular to the first direction. The interleaving shoe may be urged along the arrays or toward a multi-row termination sleeve to guide the optical fibers through the guide structure.The first row of fibers can be physically offset from and interleaved with the second row of fibers by the guiding structure.

[0008] Embodiments of the invention relate to a method of using an interleaving shoe to automatically interleave optical fibers from multiple ribbons. A non-limiting example of the method includes guiding the optical fibers into an interleaving comb in a first direction. The optical fibers comprise a first row of fibers and a second row of fibers. The interleaving comb includes a guide structure having one or more channels. Each channel is configured to receive a single optical fiber. Each channel has a first end and a second end, and the second end is offset from the first end in a second direction perpendicular to the first direction. The method includes moving the optical fibers through the interleaving comb to force the optical fibers through the guide structure.The first row of fibers is physically offset from and interleaved with the second row of fibers by the guide structure. The method includes inserting the glass fibers into a first end of an interleaving shoe and removing the interleaving comb.

[0009] Other technical features and advantages are achieved by the methods according to the present invention. Embodiments and aspects of the invention are described in detail herein and are considered part of the claimed subject matter. A better understanding can be obtained from the detailed description and the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The details of the exclusive rights described herein are particularly pointed out and expressly claimed in the claims at the conclusion of the specification. These and other features and advantages of embodiments of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings, in which: Fig. 1 illustrates an isometric view of a two-row termination sleeve before and after insertion into a nesting shoe according to one or more embodiments of the invention; Fig. 2A is a top view of the two-row termination sleeve and nesting shoe shown in Fig. 1, according to one or more embodiments of the invention; Fig. 2B is a sectional view of the two-row termination sleeve and nesting shoe shown in Fig. 1, according to one or more embodiments of the invention; Fig. 3A is a top view of the two-row termination sleeve and nesting shoe shown in Fig. 1 after the glass fibers have been partially passed through the interleaving shoe according to one or more embodiments of the invention; Fig. 3B is a sectional view of the two-row termination sleeve and nesting shoe shown in Fig. 1 after the glass fibers have been partially passed through the interleaving shoe according to one or more embodiments of the invention; Fig. 4A is a top view of the two-row termination sleeve and nesting shoe shown in Fig. 1 after the glass fibers have been guided through a first part of the interleaving shoe according to one or more embodiments of the invention; Fig. 4B is a sectional view of the two-row termination sleeve and nesting shoe shown in Fig. 1 after the glass fibers have been guided through a first part of the interleaving shoe according to one or more embodiments of the invention; Fig. 5A is a top view of the two-row termination sleeve and nesting shoe shown in Fig. 1 after the glass fibers have been passed through the interleaving shoe according to one or more embodiments of the invention; Fig. 5B is a sectional view of the two-row termination sleeve and nesting shoe shown in Fig. 1 after the glass fibers have been passed through the interleaving shoe according to one or more embodiments of the invention; Fig. 6A is a top view of the two-row termination sleeve and nesting shoe shown in Fig. 1 after the nesting shoe has been pushed over the fiber optic ribbons to the base of the dual-row termination sleeve according to one or more embodiments of the invention; Fig. 6B is a sectional view of the two-row termination sleeve and nesting shoe shown in Fig. 1 after the nesting shoe has been pushed over the fiber optic ribbons to the base of the dual-row termination sleeve according to one or more embodiments of the invention; Fig. 7 illustrates a cross-sectional view of a two-row termination sleeve being inserted into a temporary nesting comb according to one or more embodiments of the invention; Fig. 8 is a flowchart illustrating a method according to one or more embodiments of the invention; and Fig. 9 is a flowchart illustrating a method according to one or more embodiments of the invention.

[0011] The diagrams presented herein are illustrative. Numerous variations of the diagram(s) or operations described herein may be made without departing from the scope of the invention. For example, the operations may be performed in a different order, or operations may be added, omitted, or modified.

[0012] In the accompanying figures and the following detailed description of the described embodiments of the invention, the various elements illustrated in the figures are designated by two- or three-digit reference numerals. With few exceptions, the leftmost digit of each reference number corresponds to the figure in which the corresponding element is first illustrated. DETAILED DESCRIPTION

[0013] First, it should be noted that while exemplary embodiments of the invention are described in connection with a specific example of a termination sleeve design (e.g., a termination sleeve for a 2x12 ribbon of 24 fibers), embodiments of the invention are not limited to the particular termination sleeve designs described in the specification. Rather, embodiments of the present invention may be implemented in connection with any ribbon configuration (2-row, 3-row, N-row, etc.) having any number of optical fibers (an even or odd number of fibers, numerous fibers, few fibers, various combinations of fiber types, such as high NA fibers or PM-maintaining fibers, etc.).

[0014] In a general representation of technologies more specifically relevant to aspects of the present invention, fiber optic connectors are designed to handle a higher number of fiber optic cables to provide a greater number of optical communication channels. While fiber optic connectors terminating in two, eight, or 12 individual fiber optic cables are very common, for example, in some applications it is more desirable for a similar connector to terminate in 24, 32, 48, or even more fiber optic cables.

[0015] As used herein, a "single glass fiber" is one that has a glass core surrounded by a glass cladding, which is enclosed by a polymer sheath. That is, a single glass fiber differs from a fiberglass ribbon in that the former lacks a polymer matrix to hold the individual glass fibers together. As used herein, the term "exposed glass fibers" means that the polymer matrix and polymer sheath have been removed from the ribbon to expose the glass cladding.

[0016] Fiber optic connectors typically use a termination sleeve into which the individual fibers from a fiber optic ribbon or ribbons are terminated and held in place. When multiple fiber optic ribbons and their connected individual fibers are manually assembled into a termination sleeve, the process can be very time-consuming, partly due to the comparatively small and rather delicate nature of the fiber optic ribbon. Manual assembly is particularly difficult due to the small relevant dimensions, such as a typical 8-fiber ribbon being only about 2 mm wide and 0.32 mm thick, with each individual coated glass fiber within it having a diameter of only 250 microns. This is even more true for applications requiring axis alignment, such as when a PM fiber requires cross-axis rotational alignment to clock the PM in the termination sleeve.

[0017] A common practice for assembling multiple ribbons into a termination sleeve, such as a leader termination sleeve, is to assemble one ribbon at a time using a v-grooving or ribbon-forming tool. For example, the 24-fiber multi-ribbon MT-24 termination sleeve was designed with stepped rows of v-grooves inside the termination sleeve, with each row of v-grooves serving to guide and contain a ribbon. As used herein, "v-groove" refers to a groove with a generally v-shaped cross-sectional profile (sometimes called a tooth), usually located adjacent to an MT termination sleeve to increase fiber density. Typically, the bottommost ribbon, where the v-grooves are the longest, is assembled first by aligning the ribbon fibers within the channel defined by the leader v-grooves and then pushing the fibers into the connected fiber holes.A second ribbon is then assembled into a second row of v-grooves slightly shorter than the first row. Because most termination sleeves have an opening at the top, an installer can visually observe the ribbons entering each row of v-grooves. While v-grooves allow multiple ribbons to be assembled into a single termination sleeve, nesting is difficult and is usually performed manually. During assembly, fibers are placed in the correct location one at a time (or one ribbon at a time if a lateral ribbon offset requires a large clearance for bending). This process can be very time-consuming and produce a low yield.

[0018] Banding tools, which combine multiple input fibers into ribbons, also exhibit nesting issues, especially at high fiber densities. When using a banding tool, multiple fibers (e.g., from an MT or fanout block) are inserted one at a time into predetermined locations on the banding tool. Once nesting is manually achieved, the banding tool can be used to realign stacked fibers into a 1D configuration.

[0019] While both v-grooving and banding tools can ultimately deliver 1D fiber configurations, neither approach is well-suited for full automation, as both require manual intervention and careful inspection of the fibers before or during fiber nesting. It would be highly advantageous to provide a termination sleeve assembly that can automatically perform fiber nesting of any density without introducing defects or fiber misalignment.

[0020] In a general statement of aspects of the present invention, one or more embodiments of the invention address the noted deficiencies in the prior art by providing a novel interleaving shoe for dual-row termination sleeve ribbons that automatically interleaves fibers during insertion. This novel interleaving shoe includes one or more guide structures that physically displace and interleave optical fibers as the fibers are moved through channels in the guide structures during insertion.

[0021] Unlike conventional v-grooves, which run parallel to each other and straight in the direction of fiber insertion, the present guide structures can have channels designed with arbitrary offset angles relative to the insertion path. When a fiber enters a channel of the guide structure, the fiber is guided through the channel and physically deflected by the channel's offset angle. The channels can be designed so that each fiber enters a different channel, and each fiber achieves a desired amount of offset at every point along the channel's length.

[0022] The interleaving shoe itself and / or channels in the guide structure can be tapered so that each fiber is automatically and physically interleaved after sufficient offset has been achieved (at a point that can be arbitrarily defined and based on arbitrary factors, such as the fiber's stress level and the tolerable bend radii for the given application). In short, an optical fiber enters a channel and is forced into an offset by the channel path. The fiber is then forced into an interleaved position relative to other fibers by the taper of the interleaving shoe (or a taper of the guide channels, or both). Because the interleaving shoe provides a mechanism for physically and automatically offsetting and interleaving optical fibers, it is well suited for applications with a large number of fibers, such asfor single-row, high-fiber-density connectors required for silicon photonics optics connectors, while remaining compatible with commercially available standard MT components. Furthermore, the custom nature of the channels allows for arbitrary changes to the final pitch of the fibers. In some applications, the final pitch may be larger or smaller than the initial pitch of each of the rows of fibers. For example, when combining two rows of fibers, the final pitch may be twice the initial pitch (e.g., interleaving an upper row into a lower row), more than twice the initial pitch (e.g., interleaving both rows to decrease the pitch between adjacent rows), or less than twice the initial pitch (e.g., channel staggering may increase the pitch between adjacent interleaved fibers).

[0023] For a more detailed description of aspects of the present invention, Fig. 1 is an isometric view of a two-row termination sleeve 100 before (upper images) and after (lower combined image) insertion into a nesting shoe 102 according to one or more embodiments of the invention. As shown in Fig. 1, the dual-row termination sleeve 100 contains two vertically stacked rows of optical fibers 104 (also referred to as a 2D fiber array). For ease of illustration, the termination sleeve 100 is shown with a total of eight fibers in a 2x4 configuration, but it should be understood that it may contain any number of vertically stacked optical fibers, such as in a special, custom-made multi-row termination sleeve or in an industry-standard multi-row MT termination sleeve. For example, the dual-row termination sleeve 100 may contain 24 optical fibers arranged in a two-row 12-row configuration.

[0024] During insertion into the nesting shoe 102, the glass fibers 104 are physically displaced from the channels arranged in the body of the nesting shoe 102 (see Fig. 2A). Subsequently and / or simultaneously, the glass fibers 104 are nested by tapering in the channels or the body of the nesting shoe 102 (see Fig. 2B). After insertion, the optical fibers 104 exit the interleaving shoe 102 as a single row of fibers (a 1D fiber array) with twice the fiber density.

[0025] Fig. 2A to 6B show the step-by-step insertion of a two-row termination sleeve band into a nesting shoe according to one or more embodiments of the invention. Fig. Figure 2A shows a top view of the two-row termination sleeve 100 and the nesting shoe 102 shown in Fig. 1 will be shown. Fig. Figure 2B shows a sectional view of the two-row termination sleeve 100 and the nesting shoe 102 shown in Fig. 1 will be shown.

[0026] As in Fig. 2A, the two-row termination sleeve 100 may include an array of fiber optic ribbons 200. End portions of the fiber optic ribbons 200 may be removed or stripped of polymer material to expose an array of individual fiber optics 202. Although in the Fig. 2 shown top view is not visible (due to obstruction by the fibers of the upper row), is in Fig. 2 that the arrangement of glass fibers 202 has two vertically stacked rows of fibers.

[0027] As further stated in Fig. As shown in Figure 2A, the optical fibers 202 may be inserted into an opening in the nesting shoe 102. The nesting shoe 102 may include one or more channels 204 defined by a guide structure 206. In some embodiments of the invention, the channels 204 are configured such that only a single fiber of the optical fibers 202 can fit into a particular channel.

[0028] The channels 204 may be abruptly or gradually offset from the insertion axis. As shown, the channels 204 are gradually offset in a first section "A" to a final amount of offset achieved in a second section "B". In further embodiments of the invention, offsetting occurs along the entire length of the channels (i.e., "B" is small or nonexistent). For illustrative purposes, a single example of sections "A" and "B" is shown, but it should be understood that the aspect ratio between "A" and "B" may be arbitrarily chosen to achieve a given total offset over any distance, depending on the requirements of a given application.

[0029] In some embodiments of the invention, the guiding structure 206 is configured so that only fibers from a single row of the dual-row termination sleeve 100 enter channels (as shown, only the top fibers enter a channel). In this way, only one of the rows of fibers is offset within the channels (desirably, the top or bottom row). In other embodiments, the guiding structure 206 is configured so that both rows of fibers enter channels (not shown for simplicity of illustration). In this way, both rows of fibers are offset within the channels. In some embodiments of the invention, the top row is offset in a first direction, while the bottom row is offset in a second direction.Increasing the complexity of the nesting shoe 102, simultaneously offsetting both rows allows the overall offset distance to be reduced (desirably halved) and allows for an individual and specific final pitch of the fibers by offsetting the arrays accordingly.

[0030] As in Fig. 2B, the interleaving shoe 102 may be tapered to force the glass fibers 202 into a single row (a 1D array). The tapering may occur across the entire interleaving shoe 102 (as shown) or only a portion thereof. In some embodiments of the invention, the interleaving shoe 102 is constructed such that the tapering occurs after offsetting (i.e., after the Fig. 2A). In some embodiments of the invention, the nesting shoe 102 is constructed so that the taper occurs after a portion, but not all, of the displacement has occurred (i.e., a distance within the Fig. 2A). The location of this tapered section can be adjusted to ensure that sufficient fiber offset is achieved prior to interleaving and can be based, for example, on the perpendicular distance between the two rows of fibers and the pitch between adjacent fibers.

[0031] Fig. Figure 3A shows a top view of the two-row termination sleeve 100 and the nesting shoe 102 shown in Fig. 1 after the glass fibers 202 have been partially guided along the channels 204 through the section “A” of the nesting shoe 102. Fig. Figure 3B shows a sectional view of the two-row termination sleeve 100 and the nesting shoe 102 shown in Fig. 1 after the glass fibers 202 have been partially guided along the channels 204 through the section “A” of the nesting shoe 102.

[0032] As in Fig. 3B, only the upper row of fibers enters the guide structure 206, resulting in a partial displacement of the upper row of fibers (relative to the lower row of fibers). As further shown in Fig. 3B, the bottom row of fibers enters the interleaving shoe 102 and continues to travel under (bypassing) the guide structure 206 until it encounters the tapered sidewall. In some embodiments of the invention, the bottom row of fibers does not bypass the guide structure 206, but instead enters a second portion of the guide structure 206 (not shown). In this way, both the top and bottom fibers can be offset and guided into a new, interleaved output pitch, as described above.

[0033] In some embodiments of the invention, the tapering may occur after partial or complete displacement of the fibers. As in Fig. 3A and Fig. 3B, the upper row of fibers has been partially displaced when the fibers encounter the tapered sidewall of the nesting shoe 102 (the one shown in Fig. 3B). It should be noted, however, that taper can be performed before, at any point during, or after the offset of the glass fibers 202 by adjusting the sidewall configuration of the nesting shoe 102.

[0034] Fig. Figure 4A shows a top view of the two-row termination sleeve 100 and the nesting shoe 102 shown in Fig. 1 after the glass fibers 202 have been guided along the channels 204 through the section “A” and into the section “B” of the nesting shoe 102. Fig. Figure 4B shows a sectional view of the two-row termination sleeve 100 and the nesting shoe 102 shown in Fig. 1 after the glass fibers 202 have been guided along the channels 204 through the section “A” and into the section “B” of the nesting shoe 102.

[0035] As in Fig. 4A, the interleaving shoe 102 has been sufficiently guided over the glass fibers 202 so that the upper row of fibers has been completely offset from the lower row of fibers. In other words, the glass fibers 202 have entered section "B" of the interleaving shoe 102. As shown in Fig. 4B, the glass fibers 202 have struck the tapered sidewall of the nesting shoe 102. As a result, the glass fibers 202 have been pushed toward each other in the perpendicular direction (the direction in which the two rows of fibers have been vertically stacked). By comparing Fig. 4A and Fig. 4B shows that tapering of the glass fibers 202 occurs after the upper row has been at least partially offset from the lower row. This avoids collisions (and thus damage) between the upper and lower rows of fibers.

[0036] Fig. Figure 5A shows a top view of the two-row termination sleeve 100 and the nesting shoe 102 shown in Fig. 1 after the glass fibers 202 have been guided through the channels 204 of the nesting shoe 102. Fig. Figure 5B shows a sectional view of the two-row termination sleeve 100 and the nesting shoe 102 shown in Fig. 1 after the glass fibers 202 have been guided through the channels 204 of the nesting shoe 102.

[0037] As in Fig. 5A, the interleaving shoe 102 has been extended sufficiently over the optical fibers 202 so that end portions of the optical fibers 202 exit the interleaving shoe 102. At this point, the optical fibers 202 have been staggered and interleaved into a single row of fibers (a 1D fiber array). In some embodiments of the invention, the length by which each of the end portions of the optical fibers 202 extends from the interleaving shoe 102 varies (due to differences in fiber length, the path through the guide structure 206, etc.).

[0038] Fig. Figure 6A shows a top view of the two-row termination sleeve 100 and the nesting shoe 102 shown in Fig. 1 after the nesting shoe 102 has been slid over the fiber optic ribbons 200 to the base of the dual-row termination sleeve 100. Fig. Figure 6B shows a sectional view of the two-row termination sleeve 100 and the nesting shoe 102 shown in Fig. 1 after the nesting shoe 102 has been slid over the fiber optic ribbons 200 to the base of the dual-row termination sleeve 100.

[0039] As in Fig. 6A, the interleaving shoe 102 has been sufficiently guided over the glass fibers 202 so that the glass fiber ribbons 200 are completely covered. In some embodiments of the invention, the exposed end portions of the glass fibers 202 are cut to ensure that all fibers have the same exiting tip length (as stated above, some fibers may have shorter or longer fiber tip ends present in the interleaving shoe 102 for various reasons, such as some fibers being staggered and others not—staggered fibers will generally have shorter fiber tip ends). The glass fibers 202 may be cleaned and cut by any suitable method, such as laser or mechanical cutting. Cutting is also suitable for removing end portions of the glass fibers 202 that were damaged during the realignment process.In some embodiments of the invention, the nesting shoe 102 is then attached to the dual-row termination sleeve 100 to secure the fiber bends. In some embodiments of the invention, the nesting shoe 102 is adhesively bonded to the dual-row termination sleeve 100, although other methods for bonding the nesting shoe 102 to the dual-row termination sleeve 100 or to the fiber assemblies are contemplated within the scope of the invention. In some embodiments of the invention, the nesting shoe 102 includes a latch (not shown) for locking to the dual-row termination sleeve 100. In other embodiments of the invention, the nesting shoe is attached directly to the multi-fiber assemblies (not shown). In this way, the nesting shoe can even be used in applications that do not include a termination sleeve.

[0040] Fig. 7 shows a cross-sectional view of the two-row termination sleeve 100 being inserted into a temporary nesting comb 700 according to one or more embodiments of the invention. As shown in Fig. 7, the above-discussed guide structure 206 need not be limited to the nesting shoe 102. In some embodiments of the invention, the guide structure 206 is instead housed within a temporary nesting comb 700.

[0041] The optical fibers 202 are staggered and interleaved using the interleaving comb 700 in a manner similar to that described above for the interleaving shoe 102. For example, the optical fibers 202 may be guided within the interleaving comb 700 by the guide structure 206 to physically stagger and interleave the optical fibers 202.

[0042] After the glass fibers 202 are interleaved into a single row of fibers, a shoe 702 can advantageously be passed over the glass fibers 202 and the interleaving comb 700 can be removed. The shoe 702 can then be fixed to the two-row termination sleeve 100 and the glass fibers 202 can be terminated in a similar manner as described above for Fig. 6A and Fig. 6B described.

[0043] Arranging the guide structure 206 in a temporary nesting comb 700 allows the guide structure 206 to be reused as often as required. The disadvantage, of course, is the higher cost of manufacturing the nesting comb 700 in addition to the shoe 702. In short, a temporary nesting shoe is well suited for repeated applications, such as fiber series with numerous termination sleeves of the same pitch (so that the same guide structure 206 serves for each termination sleeve).

[0044] Fig. Figure 8 depicts a flowchart 800 illustrating a method for nesting an array of optical fibers in a termination sleeve according to one or more embodiments of the invention. As shown in block 802, the optical fibers are inserted into a first end of an interleaving shoe. In some embodiments of the invention, the optical fibers include a first row of fibers and a second row of fibers.

[0045] In some embodiments of the invention, the nesting shoe includes a body having a first end configured to pass over a termination sleeve band and a second end opposite the first end. The second end may include an opening. In some embodiments of the invention, the body is tapered in a first direction between the first end and the second end.

[0046] In some embodiments of the invention, a guiding structure is disposed within the body. The guiding structure may include one or more channels, and each channel may be configured to receive a single optical fiber. In some embodiments of the invention, each channel has a first end and a second end, and the second end is offset from the first end in a second direction perpendicular to the first direction.

[0047] In some embodiments of the invention, the guiding structure is configured to receive optical fibers only from a first row of a dual-row termination sleeve. In some embodiments of the invention, the guiding structure is configured so that a second row of the dual-row termination sleeve bypasses the guiding structure. In some embodiments of the invention, the guiding structure is configured to receive optical fibers from both rows of a dual-row termination sleeve. In some embodiments of the invention, the guiding structure includes one or more upper channels and one or more lower channels. In some embodiments of the invention, the guiding structure is configured to ensure that the maximum fiber bend during staggering is within allowable fiber bend radii for the given application.In some embodiments of the invention, the allowable fiber bend radius is predetermined based on a given application or fiber type.

[0048] In some embodiments of the invention, each channel in the guide structure has a first section and a second section. In some embodiments of the invention, the displacement of each channel occurs within the first section but not the second section. In some embodiments of the invention, the displacement of each channel occurs within the first section and the second section. In some embodiments of the invention, a majority of the displacement of each channel occurs within the first section (with a small portion of the total displacement occurring in the second section).

[0049] In some embodiments of the invention, each channel is tapered. In some embodiments of the invention, the tapering of each channel occurs within the second section but not the first section.

[0050] At block 804, the interleaving shoe is pushed toward the termination sleeve to guide the optical fibers through the guide structure. In some embodiments of the invention, the first row of fibers is physically offset from and interleaved with the second row of fibers by the guide structure. Even if the offset is initially imperfect (in terms of tolerance and initial pitch variation of the fiber array), the nature of the cylindrical fibers means that each fiber will interact by contact as they converge to complete the interleaving offset.

[0051] The method may further include coupling the nesting shoe to the termination sleeve. In some embodiments of the invention, the nesting shoe is bonded to the termination sleeve using an adhesive. In some embodiments of the invention, the nesting shoe is snapped to the termination sleeve using a snap connector incorporated into the nesting shoe or the termination sleeve. In some embodiments of the invention, after the fibers are guided through the guide structure, the fibers are cleaned and cut (since they might otherwise protrude from the nesting shoe at different distances).

[0052] In some embodiments of the invention, a fiber tip is cut from one or more optical fibers. In some embodiments of the invention, cutting the fiber tip(s) includes laser or mechanical cutting. In some embodiments of the invention, the one or more optical fibers are cut such that each of the one or more optical fibers protrudes from the nesting shoe by the same length.

[0053] Fig. Figure 9 depicts a flowchart 900 illustrating a method for interleaving an array of optical fibers in a termination sleeve according to one or more embodiments of the invention. As shown in block 902, the optical fibers are inserted into an interleaving comb in a first direction. In some embodiments of the invention, the optical fibers include a first row of fibers and a second row of fibers.

[0054] In some embodiments of the invention, the interleaving comb includes a guide structure. In some embodiments of the invention, the guide structure includes one or more channels, and each channel is configured to receive a single optical fiber. In some embodiments of the invention, each channel includes a first end and a second end, and the second end is offset from the first end in a second direction perpendicular to the first direction.

[0055] At block 904, the optical fibers are moved (guided) by the interleaving comb to push the optical fibers through the guide structure. In some embodiments of the invention, the first row of fibers is physically offset from and interleaved with the second row of fibers by the guide structure. The optical fibers can be guided through the guide structure by physically moving the fibers into the interleaving comb, by moving the interleaving comb over the fibers, or by a combination of opposing movements of the fibers and comb. In some embodiments of the invention, the interleaving comb is divided into several movable sections (not shown), and each can be guided around the top and bottom rows of the fiber array.The offsetting of the upper and lower rows of fiber arrays can then be performed by moving the various sections to gradually shift the fiber array to a given offset and pitch before inserting the nesting shoe.

[0056] At block 906, the optical fibers are inserted into an interleaving shoe. The interleaving shoe may include a body having a first end configured to pass over a termination sleeve band and a second end opposite the first end. The second end may include an opening. In some embodiments of the invention, the body is tapered in a first direction between the first end and the second end. At block 908, the interleaving comb is removed.

[0057] The method may further include moving the interleaving shoe over the glass fibers until contact is made with the termination sleeve. In this way, the glass fibers are forced through and out of the interleaving shoe. In some embodiments of the invention, the interleaving shoe is bonded to the termination sleeve using an adhesive. In some embodiments of the invention, one or more glass fibers are cut so that each of the glass fibers protrudes from the interleaving shoe by the same length.

[0058] Various embodiments of the invention are described herein with reference to the corresponding drawings. Alternative embodiments may be developed without departing from the scope of the invention. Although the following description and the drawings recite various connections and positional relationships (e.g., above, below, adjacent, etc.) between elements, those skilled in the art will appreciate that many of the positional relationships described herein are orientation-independent if the described functionality is retained even when the orientation changes. These connections and / or positional relationships may be direct or indirect, unless otherwise stated, and the present invention is not intended to be limiting in this regard.Similarly, the term "coupled" and variations thereof describe the presence of a communication path between two elements and does not imply a direct connection between the elements without intervening elements / connections. All such variations are considered part of the present invention. Accordingly, a coupling of units may denote a direct or an indirect coupling, and a positional relationship between units may be a direct or an indirect positional relationship. As an example of an indirect positional relationship, reference in the present description to forming a layer "A" above a layer "B" includes situations where one or more intermediate layers (e.g., layer "C") are arranged between layer "A" and layer "B", as long as the relevant features and functionalities of layer "A" and layer "B" are not substantially altered by the intervening layer(s).

[0059] The following definitions and abbreviations are intended to be used in interpreting the claims and the description. As used herein, the terms "comprises," "having," "includes," "including," "has," "having," "contains," or "containing," or any other variations thereof, are intended to cover non-exclusive inclusion. For example, a composition, mixture, process, method, article, or device that comprises a group of elements is not necessarily limited to only those elements, but may also include other elements not expressly listed or inherent in that composition, mixture, process, method, article, or device.

[0060] Furthermore, the term "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or configuration described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments or configurations. The terms "at least one" and "one or more" are to be construed to include any integer greater than or equal to one, i.e., one, two, three, four, and so on. The term "a plurality" is intended to include any integer greater than or equal to two, i.e., two, three, four, five, and so on. The term "connection" can include an indirect "connection" and a direct "connection."

[0061] Throughout the specification, references to "one embodiment," "an embodiment," "an example embodiment," etc., mean that the described embodiment may include a particular element, structure, or feature, but each embodiment may or may not include the particular element, structure, or feature. Further, these terms do not necessarily refer to the same embodiment. Where a particular element, structure, or feature is described in connection with one embodiment, it is understood that it is within the skill of one skilled in the art to practice that element, structure, or feature in connection with other embodiments, whether expressly described or not.

[0062] For the purposes of the following description, the terms "upper", "lower", "right", "left", "vertical", "horizontal", "above", "top", "below" and derivatives thereof shall refer to the described structures and methods as oriented in the drawings of the figures. The terms "overlying", "above", "on", "disposed on" or "disposed above" mean that a first element, such as a first structure, is present on a second element, such as a second structure, wherein intervening elements, such as an interface structure, may be present between the first element and the second element. The term "direct contact" means that a first element, such as a first structure, and a second element, such as a second structure, are connected at the interface of the two elements without intervening conductor, insulator or semiconductor layers.

[0063] Spatial relative terms such as "beneath," "under," "lower," "above," "upper," and the like are used herein for convenience of description to describe the relationship of one element or feature to another element(s) or feature(s) as illustrated in the figures. It should be noted that the spatial relative terms are intended to include various orientations of the unit in operation, in addition to the orientations illustrated in the figures. For example, if the unit is turned over in the figures, elements described as being "below" or "below" other elements or features will then be located "above" the other elements or features. Thus, the term "below" can include an orientation of both above and below. The unit can also be oriented differently (e.g.,rotated by 90 degrees or in other orientations) and the spatial relative descriptive terms used herein can be interpreted accordingly.

[0064] The terms "about," "substantially," "approximately," and variations thereof are intended to cover the degree of error associated with measuring the respective quantity with equipment available at the time the application is filed. For example, "about" may include a range of ± 8%, 5%, or 2% of a given value.

[0065] The flowcharts and block diagrams in the figures illustrate possible implementations of manufacturing and / or operating methods according to various embodiments of the present invention. Various functions / operational steps of the method are represented by blocks in the flowchart. In some alternative implementations, the functions indicated in the blocks may be in a different order than indicated in the figures. For example, two blocks shown in succession may actually execute substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending on the functionality involved.

[0066] The descriptions of the various embodiments of the present invention have been given for purposes of illustration, but are not intended to be exhaustive or limited to the form disclosed. Numerous modifications and variations will be apparent to those skilled in the art without departing from the scope of the described embodiments. The terminology used herein has been chosen to best describe the principles of the embodiments, practical application, or technical improvement over technologies on the market, or to enable others skilled in the art to understand the embodiments disclosed herein.

[0067] In a preferred embodiment of the present invention described herein, there is provided a method for interleaving optical fiber assemblies of multiple ribbons, the method including: feeding the optical fibers into an interleaving comb in a first direction, the optical fibers having a first row of fibers and a second row of fibers, the interleaving comb comprising: a guide structure having one or more channels, each channel adapted to receive a single optical fiber, each channel having a first end and a second end, the second end being offset relative to the first end in a second direction perpendicular to the first direction;Moving the interleaving comb to guide the glass fibers through the guide structure, wherein the first row of fibers is physically offset from and interleaved with the second row of fibers by moving through the guide structure; Inserting the glass fibers into a first end of an interleaving shoe having a body having the first end and a second end opposite the first end, the second end having an opening, the body being tapered in a first direction between the first end and the second end;and removing the interleaving comb. The method may further comprise moving the interleaving shoe over the optical fibers until contact is made with a multi-band termination sleeve. The interleaving shoe may be bonded to the termination sleeve using an adhesive. One or more optical fibers may be cut so that each of the optical fibers protrudes from the interleaving shoe by the same length.

Claims

[1] Interleaving shoe (102) for a multi-fiber arrangement, the interleaving shoe (102) comprising: a body having a first end adapted for insertion over the multi-fiber assembly and a second end opposite the first end, the second end having an opening, the body being tapered in a first direction between the first end and the second end; and a guide structure (206) disposed within the body, the guide structure (206) being configured to receive optical fibers (104, 202) from both rows of a dual-row termination sleeve (100), the guide structure (206) comprising a plurality of channels (204), each channel (204) being configured to receive a single optical fiber (104, 202), each channel (204) having a first end and a second end, the second end being offset from the first end in a second direction perpendicular to the first direction, and the first ends of the channels (204) being arranged in vertically stacked rows, the vertically stacked rows being arranged at the first ends of the channels (204) without offset along the second direction. [2] The nesting shoe (102) of claim 1, wherein each channel (204) has a first portion (A) and a second portion (B). [3] The nesting shoe (102) of claim 2, wherein the displacement of each channel (204) occurs within the first section (A) but not the second section (B). [4] The nesting shoe (102) of claim 2, wherein the offset of each channel (204) occurs within the first section (A) and the second section (B). [5] The nesting shoe (102) of claim 2, wherein each channel (204) is tapered. [6] The nesting shoe (102) of claim 5, wherein the taper of each channel (204) occurs within the second portion (B) but not the first portion (A). [7] The nesting shoe (102) of claim 1, wherein the guide structure (206) is configured to receive glass fibers (104, 202) having a first pitch and to nest the glass fibers (104, 202) having a second pitch that is greater or smaller than the first pitch. [8] The interleaving shoe (102) of claim 1, wherein the multi-fiber assembly terminates in a multi-row multi-port (MT) termination sleeve (100). [9] Nesting shoe (102) according to claim 8, wherein the guide structure (206) has one or more upper channels (204) and one or more lower channels (204). [10] A method (800) for interleaving arrays of optical fibers (104, 202) exiting both rows of a dual-row termination sleeve (100), the method comprising: Inserting (802) the arrays of glass fibers (104, 202) into a first end of an interleaving shoe (102), the arrays of glass fibers (104, 202) comprising a first row of fibers and a second row of fibers, the interleaving shoe (102) comprising: a body having a first end adapted for insertion over a termination sleeve band and a second end opposite the first end, the second end having an opening, the body being tapered in a first direction between the first end and the second end; and a guide structure (206) disposed within the body, the guide structure (206) having a plurality of channels (204), each channel (204) configured to receive a single optical fiber (104, 202), each channel (104, 202) having a first end and a second end, the second end being offset from the first end in a second direction perpendicular to the first direction, and the first ends of the channels (204) being arranged in vertically stacked rows, the vertically stacked rows being arranged at the first ends of the channels (204) without offset along the second direction; and Pressing (804) the nesting shoe (102) toward the termination sleeve (100) to guide the glass fibers (104, 202) through the guide structure (206); wherein the first row of fibers is physically offset from and interleaved with the second row of fibers by the guide structure (206). [11] The method of claim 10, further comprising coupling the nesting shoe (102) to the multi-row termination sleeve (100). [12] The method of claim 10, wherein the guide structure (206) is configured such that a maximum bend of each fiber within the guide structure (206) is within an allowable fiber bend radius. [13] The method of claim 10, further comprising cutting a fiber tip of one or more glass fibers (104, 202). [14] The method of claim 13, wherein cutting the fiber tip comprises laser or mechanical cutting. [15] The method of claim 14, wherein the one or more glass fibers (104, 202) are cut such that each of the one or more glass fibers (104, 202) protrudes from the nesting shoe (102) by the same length.

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