Multi-fiber ferrule with tapered transition to ferrule bore - Patent 7222247

Abstract

The present disclosure relates to a multi-fiber ferrule having multiple bores, each having adjacent divider sections separating the bores, which further facilitates the insertion of an optical fiber into each bore.

Description

[Technical Field]

[0001]

[0001] (Priority Application) This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 399,814, filed August 22, 2022, the contents of which are hereby relied upon and incorporated by reference in their entirety.

[0002] This disclosure relates generally to optical fibers, and more particularly to ferrules for multi-fiber optical connectors and optical connector and cable assemblies including such ferrules, and methods relating to these components. [Background technology]

[0003]

[0003] Optical fibers are useful in a wide variety of applications, including telecommunications for voice, video, and data transmission. In telecommunications systems using optical fibers, the fiber optic cable carrying the optical fibers typically has many points at which it connects to equipment or to other fiber optic cables. To conveniently provide these connections, optical connectors are often provided at the ends of the fiber optic cable. The process of terminating individual optical fibers from a fiber optic cable is called "connectorization." Connectorization can also be performed in the factory to obtain "pre-connectorized" or "pre-terminated" fiber optic cables, or in the field (e.g., using "field-installable" connectors).

[0004]

[0004] There are many different types of optical connectors. In environments requiring high-density interconnections and / or high bandwidth, such as data centers, multi-fiber optical connectors are most widely used. One example is the multi-fiber push-on (MPO) connector, which incorporates mechanical transfer (MT) ferrules and is standardized according to TIA-604-5 and IEC 61754-7. These connectors can achieve very high optical fiber densities and can reduce the amount of hardware, space, and effort required to establish a large number of interconnections.

[0005]

[0005] Despite the widespread use of MPO connectors in data center environments, there are still challenges / issues that must be addressed. For example, inserting optical fibers into MPO connectors can be challenging. MPO connector ferrules can have one of the following characteristics: (1) they stop the optical fibers during ferrule insertion, preventing the optical fibers from progressing through the ferrule's microholes, or (2) they cross over each other during ferrule insertion, causing the optical fibers to enter the microholes of adjacent ferrules, resulting in the optical fibers not matching the microholes of their respective ferrules.

[0006] Additionally, securing an optical fiber within the ferrule of an MPO connector can be challenging. Typically, an adhesive material is used for this purpose, and the adhesive material is injected or otherwise dispensed into the internal cavity of the ferrule. Sufficient adhesive material must be present to ensure that the optical fiber is adequately bonded / secured to the ferrule. To avoid uncertainty about whether a sufficient amount of adhesive material has been dispensed, one may be tempted to completely fill the internal cavity of the ferrule. However, doing so increases the likelihood that the adhesive material will accumulate on the exterior of the ferrule or escape from the ferrule, either of which may interfere with the proper operation of the ferrule as part of the optical connector. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] U.S. Provisional Patent Application No. 63 / 399,814 [Patent Document 2] International Publication No. 2021217050A1 Summary of the Invention [Problem to be solved by the invention]

[0008]

[0007] New multi-fiber ferrule and connector designs have been proposed, including smaller multi-fiber ferrules and extremely small form factor connectors containing such ferrules. However, the structural features of these new ferrule designs still present challenges for fiber insertion and bonding.

[0009]

[0008] Improvements in the above areas are desirable. [Means for solving the problem]

[0010]

[0009] The present disclosure relates to a multi-fiber ferrule having multiple bores, each having an adjacent divider portion separating the bores, which further facilitates the insertion of an optical fiber into each bore.

[0011] In one embodiment, a ferrule for an optical connector configured to receive a plurality of optical fibers is provided, the ferrule comprising: a body having a front end and a rear end, the body extending longitudinally between the front end and the rear end; a plurality of bores extending into the body from the front end toward the rear end, each bore configured to receive one of the plurality of optical fibers; and a plurality of tapered divider portions, each tapered divider portion having a first end adjacent a respective one of the plurality of bores and a second end proximate the rear end of the ferrule, a cross-sectional shape at the first end extending around each of the plurality of bores to separate the bores from one another, and a tapered surface from the second end to the first end.

[0012] In another embodiment, the rear end of the ferrule includes indicia, whereby the indicia provide a visual indicator of the horizontal alignment of the optical fibers within the bores of the ferrule. In another embodiment, the indicia extend from the rear end of the ferrule to the second end of the tapered divider section. In another embodiment, the tapered divider section has a height H1 at the first end and a height H2 at the second end, where the height ratio H2:H1 is in the range of 1.2:1 to 3:1. In another embodiment, the tapered divider section has a width W1 at the first end and a width W2 at the second end, where the width ratio W2:W1 is in the range of 1.2:1 to 3:1. In another embodiment, the tapered divider section has a circular cross-section at the first end and a square cross-section at the second end. In another embodiment, the tapered surface of the tapered divider section has an angle in the range of 15° to 45° relative to the longitudinal axis of one of the bores. In another embodiment, adjacent tapered divider sections have corresponding adjacent tapered surfaces forming an edge configured to prevent insertion of an optical fiber into a non-corresponding bore. In another embodiment, the second end of the tapered divider section is flush with the rear end of the ferrule. In another embodiment, the plurality of bores comprises a first row of bores and a second row of bores spaced from the first row of bores, the bores in the first row being coplanar with one another and the bores in the second row being coplanar with one another. In another embodiment, the first row of bores and the second row of bores are separated by a spacer that is flush with the rear end of the ferrule, the spacer being integrally formed with the ferrule. In another embodiment, the ferrule further comprises a window formed in an upper or lower surface of the ferrule, the window extending into the lead-in section of the ferrule adjacent the tapered divider section.

[0013]

[0012] In another embodiment, an optical connector is provided comprising: a ferrule according to any of the above embodiments; and a plurality of optical fibers secured to the ferrule, each optical fiber extending from the rear end of the body into one of the microholes. In another embodiment, the plurality of bores comprises a first row of bores and a second row of bores spaced from the first row of bores, the bores in the first row being coplanar with one another and the bores in the second row being coplanar with one another. In another embodiment, the plurality of optical fibers comprises a first ribbon of optical fiber and a second ribbon of optical fiber, the first ribbon of optical fiber and the second ribbon of optical fiber being coplanar with one another and separated by an optical fiber spacer, the first ribbon of optical fiber, the second ribbon of optical fiber and the optical fiber spacer being inserted into the rear end of the ferrule such that the first ribbon of optical fiber is inserted into the first row of bores and the second ribbon of optical fiber is inserted into the second row of bores. In another embodiment, the first row of bores and the second row of bores are separated by a spacer that is flush with the back end of the ferrule, the spacer being integrally formed with the ferrule. In another embodiment, the plurality of optical fibers comprises a first ribbon of optical fibers and a second ribbon of optical fibers, the first ribbon of optical fibers and the second ribbon of optical fibers being coplanar with one another, and the first ribbon of optical fibers and the second ribbon of optical fibers being inserted into the back end of the ferrule such that the first ribbon of optical fibers is inserted into the first row of bores and the second ribbon of optical fibers is inserted into the second row of bores.

[0014]

[0013] In another embodiment, a method for terminating multiple optical fibers with a ferrule according to any of the above embodiments is provided, the method comprising aligning the optical fibers with bores in the ferrule and extending the optical fibers through a rear end of the ferrule into the bores, the tapered divider section causing one optical fiber to extend through each of the bores. In another embodiment, the aligning comprises aligning a first ribbon of optical fibers with a first row of bores and aligning a second ribbon of optical fibers with a second row of bores. In another embodiment, aligning the first ribbon of optical fibers comprises aligning optical fibers of the first ribbon with indicia at the rear end of the ferrule, and aligning the second ribbon of optical fibers comprises aligning optical fibers of the second ribbon with indicia at the rear end of the ferrule. In another embodiment, the first ribbon of optical fibers and the second ribbon of optical fibers are separated by an optical fiber spacer that is inserted into the ferrule along with the first ribbon of optical fibers and the second ribbon of optical fibers. In another embodiment, the method further comprises dispensing adhesive into the tapered divider portion. In another embodiment, the adhesive is dispensed into the bore through a window formed in the top surface of the ferrule and extending into the lead-in section of the ferrule adjacent the tapered divider portion.

[0015]

[0014] Additional features and advantages are set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art of optical communications. It is to be understood that the foregoing general description, the following detailed description, and the accompanying drawings are exemplary only and are intended to provide an overview or framework for understanding the nature and character of the claims.

[0016] The accompanying drawings are included to provide a further understanding, and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiments and, together with the description, serve to explain the principles and operation of various embodiments. Features and attributes associated with any of the embodiments shown or described may also apply to other embodiments shown, described, or evaluated based on this disclosure. [Brief explanation of the drawings]

[0017] [Figure 1] 1 is a perspective view of an embodiment of an optical connector. [Figure 2] FIG. 2 is an exploded perspective view of the optical connector of FIG. 1. [Figure 3] 2 is a front perspective view of a ferrule used in the optical connector of FIG. 1 according to the present disclosure. [Figure 4] FIG. 4 is a rear perspective view of the ferrule of FIG. 3. [Figure 5] FIG. 5 is an enlarged rear view of the ferrule of FIG. 4. [Figure 6] FIG. 6 is a cross-sectional perspective view of the ferrule of FIG. 5. [Figure 7] FIG. 10 is a rear perspective view of an alternative embodiment of a ferrule according to the present disclosure. [Figure 7A] 1 is a cross-sectional view of a ferrule and optical fiber of the present disclosure, showing the location of the binder. [Figure 7B] 1 is a cross-sectional view of a ferrule and optical fiber of the present disclosure, showing the location of the binder. [Figure 7C] 1 is a cross-sectional view of a ferrule and optical fiber of the present disclosure, showing the location of the binder. [Figure 8A] FIG. 4 is a rear perspective view of the ferrule of FIG. 3 prior to inserting an optical fiber into the ferrule in accordance with the present disclosure. [Figure 8B] 8B is a rear perspective view of the ferrule of FIG. 8A after inserting an optical fiber into the ferrule in accordance with the present disclosure. [Figure 9A]FIG. 4 is a rear perspective view of an alternative embodiment of the ferrule of FIG. 3 prior to inserting an optical fiber into the ferrule in accordance with the present disclosure. [Figure 9B] 8B is a rear perspective view of the ferrule of FIG. 8A after inserting an optical fiber into the ferrule in accordance with the present disclosure. [Figure 10] FIG. 1 is an exploded view of a ferrule of the present disclosure and a converter coupled to the ferrule according to the present disclosure. [Figure 11] FIG. 11 is a perspective view of the ferrule and converter of FIG. 10 in a state where they are integrally connected. [Figure 12] FIG. 12 is a cross-sectional view of the coupled ferrule and converter of FIG. [Figure 13] FIG. 13 is a rear view of the coupled ferrule and converter of FIG. [Figure 14] FIG. 10 is a perspective view of an alternative embodiment of a converter coupled to a ferrule according to the present disclosure. [Figure 15] FIG. 14 is a cross-sectional view of the coupled ferrule and converter of FIG. 13. [Figure 16] FIG. 14 is a rear perspective view of the ferrule and converter of FIG. 13. DETAILED DESCRIPTION OF THE INVENTION

[0018]

[0035] The following description will further clarify various embodiments through examples. Generally, the description relates to multi-fiber ferrules and fiber optic connectors and cable assemblies incorporating such multi-fiber ferrules. Specifically, the present disclosure relates to multi-fiber ferrules having multiple bores, each having adjacent divider sections separating the bores. The divider sections further facilitate the insertion of an optical fiber into each bore.

[0019]

[0036] The fiber optic connector may be based on known connector designs, such as an MPO connector. To this end, FIGS. 1 and 2 depict an optical fiber connector 10 (also referred to as an "optical connector" or simply "connector") in the form of an MTP® connector (MTP® is a trademark of US Conec Ltd.), a specific type of MPO connector. Because the multi-fiber ferrules and other components shown in subsequent figures may be used in connection with connectors of the same type as connector 10, a brief overview of connector 10 will be provided for ease of discussion. However, those skilled in the art of optical connectivity will understand that connector 10 is merely an example, and that the general principles disclosed with respect to the multi-fiber ferrules and other components shown in subsequent figures are applicable to other connector designs.

[0020]

[0037] As shown in FIG. 1, a connector 10 may be adapted to be installed on a fiber optic cable 12 ("cable") to form a fiber optic cable assembly 14. The connector includes a ferrule 16, a housing 18 received over the ferrule 16, a slider 20 received over the housing 18, and a boot 22 received over the cable 12. The ferrule 16 is spring-loaded within the housing 18 such that a front portion 24 of the ferrule 16 extends beyond a front end 26 of the housing 18. As discussed in more detail herein, the ferrule 16 may further be coupled to a converter 80 to increase the size of the ferrule 16 so that it is compatible with a particular connector configuration. An optical fiber (not shown) carried by the cable 12 extends through a microhole or bore 25 in the ferrule 16 before terminating at or near an end face 30 of the ferrule 16. The optical fiber is secured within the ferrule 16 using an adhesive material (e.g., epoxy) and is provided to optically couple with the optical fiber of a mating component (e.g., another optical fiber connector, not shown) when the housing 20 is inserted into an adapter, receptacle, etc.

[0021]

[0038] As shown in FIG. 2, connector 10 further includes ferrule boot 32, guide pin assembly 34, spring 36, crimp body 38, and crimp collar 40. Ferrule boot 32 is received in rear portion 42 of ferrule 16 to help support the optical fiber extending into ferrule bore 25 (FIG. 3). Guide pin assembly 34 includes a pair of guide pins 44 extending from pin keepers 46. Features on pin keepers 46 cooperate with features on guide pins 44 to retain portions of guide pins 44 within pin keepers 46. When connector 10 is assembled, pin keepers 46 are placed against the rear surface of ferrule 16, and guide pins 44 extend through pin holes 31, 33 (FIG. 3) in ferrule 16 beyond front end face 30.

[0022]

[0039] Both the ferrule 16 and the guide pin assembly 34 are biased toward an advanced position relative to the housing 18 by a spring 36. More specifically, the spring 36 is disposed between a pin keeper 46 and a portion of the crimp body 38. The crimp body 38 is inserted into the housing 18 when the connector 10 is assembled and includes a latch arm 50 that engages a recess 52 in the housing. At this point, the spring 36 is compressed, exerting a biasing force on the ferrule 16 through the pin keeper 46. The rear portion 42 of the ferrule defines a flange that interacts with a shoulder or stop formed in the housing 18 to retain the rear portion 42 within the housing 18.

[0023]

[0040] In one manner not shown, aramid yarn or other strength member from cable 12 is placed over end portion 54 of crimp body 38 that projects rearwardly from housing 18. The aramid yarn is secured to end portion 54 by sliding crimp ring 40 over end portion 54, which is deformed after placement of the aramid yarn. Boot 22, as shown in FIG. 1, covers this area and provides strain relief for the optical fiber by limiting the extent to which connector 10 can bend relative to cable 12.

[0024]

[0041] Now that an overall overview of connector 10 has been provided, the ferrule design will now be described. To this end, FIGS. 3 and 4 depict a ferrule 16 used in accordance with connector 10. Ferrule 16 is shown as a miniature MT ferrule, which is smaller than a conventional MT ferrule. A similar ferrule is disclosed in International Publication No. WO 2021217050 A1, the disclosure of which is incorporated by reference. However, the illustrated ferrule 16 is merely an example for illustrative purposes, and aspects of the present disclosure may be applied to conventional MT ferrules or other multi-fiber ferrule designs for MPO connectors.

[0025]

[0042] The ferrule 16 includes a ferrule body 17 that extends longitudinally (i.e., along a longitudinal axis L) between a forward end 19 and a rearward end 21. The forward end 19 of the ferrule body 17 defines an end face 23 that includes microholes 25.

[0026]

[0043] As shown in FIG. 3 , the ferrule 16 includes first and second groups 27, 29 of microholes 25 extending from the front end 19 into the ferrule body 17, with the microholes 25 of group 27 coplanar with one another, i.e., on plane P1, and the microholes 25 of group 29 coplanar with one another, i.e., on plane P2. Each microhole 25 is configured to receive an optical fiber 67 ( FIGS. 7A-7C ). In the illustrated embodiment, there are 12 microholes 25 in each of the first and second groups 27, 29. However, it is within the scope of this disclosure for alternative groupings and numbers of microholes 25 to be used with the ferrule 16 (e.g., a row of 12 microholes, etc.). The ferrule 16 also includes a recessed portion 28 in the top surface 32 of the ferrule 16. Specifically, as shown, the recessed portion 28 is defined by a ledge A in the top surface TS of the ferrule 16. As discussed in more detail herein, ledge A is configured to couple to converter 80 to form ferrule assembly 70. Recessed portion 28 and ledge A are also provided on bottom surface BS of ferrule 16. However, it is within the scope of this disclosure that in alternative embodiments, ledge A and recessed portion 28 may be provided independently on either top surface TS or bottom surface BS.

[0027]

[0044] The ferrule 16 further includes pin holes 31, 33 configured to receive guide pins during installation of the ferrule 16 within the connector 10. As shown in Figures 3 and 4, the pin holes 31, 33 are empty and the embodiment depicts a female configuration of the ferrule 16. For a male configuration, each guide pin would be received in a pin hole 31, 33 and would protrude beyond the front end 19 of the ferrule 16. Although two pin holes 31, 33 are shown in the figures, any number of pin holes 31, 33 may be provided in alternative embodiments.

[0028]

[0045] 4 and 5, the rear end 21 of the ferrule 16 is shown, including a lead-in section 35 that provides access to a bore 37 within the ferrule body 17 that extends to the forward end 19 of the ferrule 16. In some embodiments, the bore 37 includes microholes 25 that extend from the forward end 19 of the ferrule 16 into the ferrule body 17. Specifically, and briefly referring to FIG. 6, the bores 37 are adjacent to the microholes 25, and as shown, each bore 37 has a larger diameter than the microholes 25. Also, in some embodiments, the bores 37 may increase in diameter as the bores 37 approach the rear end 21, as shown. However, it is within the scope of this disclosure for the bores 37 to have a uniform diameter within the ferrule body 17 of the ferrule 16. As previously mentioned, there are two groups 27, 29 of microholes 25, and therefore two groups 27, 29 of bores 37 corresponding to the groups of microholes 25. The groups 27, 29 are separated by spacers 39. The spacers 39 are configured to separate the groups 27, 29 of bores 37 to facilitate the insertion of optical fibers into the bores 37. Specifically, the spacers 39 prevent the insertion of optical fibers 67 (FIGS. 7A-7C) or optical fiber ribbons 59, 61 (FIGS. 8 and 9) into the wrong group of bores 37. In some embodiments, the spacers 39 are integrally formed with the ferrule 16 and are flush with the rear end 21. However, in alternative embodiments, the spacers 39 are not included in the design of the ferrule 16. In another alternative embodiment, the spacers 39 are included in the lead-in section 35 of the ferrule 16 and are integrally formed with the ferrule 16, but the spacers 39 are not flush with the rear end 21 of the ferrule 16. Additional details regarding the rear end 21 of the ferrule 16 are discussed in more detail below.

[0029]

[0046] 5, an enlarged view of the lead-in section 35 of the rear end 21 is shown. As previously mentioned, the lead-in section 35 provides access to the bore 37 within the ferrule 16. As shown, the lead-in section 35 includes a channel 45 and an opening 47 that extend from the rear end 21 of the ferrule 16 to a tapered divider portion 49. In some embodiments, the lead-in section 35 includes only the opening 47, with the tapered divider portion 49 flush with the opening 47 and no channel. In some embodiments, the opening 47 of the lead-in section 35 is flush with the rear end 21. In some embodiments, the opening 47 is recessed relative to the rear end 21. The opening 47 provides access to the tapered divider portion 49 and is shaped to encompass the bore 37 and the tapered divider portion 49. The opening 47 further includes at least one indicia 51. The indicia 51 are configured to provide an installer with a reference point when installing the optical fiber ribbons 59, 61 ( FIGS. 8 and 9 ) or the optical fibers 67 ( FIGS. 7A-7C ). Specifically, the indicia 51 provide a visual indicator for horizontally aligning the optical fibers 67 or the optical fiber ribbons 59, 61 within the opening 47. The indicia 51 may also extend into the tapered divider section 49 and the bore 37 such that the indicia 51 is aligned with the center C of the bore 37. In this configuration, the indicia 51 further provides a visual indicator for aligning the distal fibers of the optical fiber ribbons 59, 61 so that the distal optical fibers of the optical fiber ribbons 59, 61 are aligned with the distal bore 37. In some embodiments, the indicia 51 is an indentation in the rear end 21 of the ferrule 16. In some embodiments, the indicia 51 is a protrusion in the rear end 21 of the ferrule 16. In some embodiments, as shown, indicia 51 comprises a mark extending from one of the openings 47 along rear end 21 toward either the top or bottom surface of ferrule 16, the mark comprising a portion of rear end 21. In some embodiments, also as shown, indicia 51 comprises a mark extending from one of the openings 47 toward either the top or bottom surface of ferrule 16, or both.

[0030]

[0047] When an optical fiber 67 or optical fiber ribbon 59, 61 is inserted into the opening 47, the optical fiber(s) engage the tapered divider section 49 before entering the bore 37. With reference to Figures 5 and 6, the tapered divider section 49 is configured to provide a physical barrier such that the optical fiber is directed into the corresponding bore 37 and optical fiber crossing is avoided. As used herein, optical fiber crossing refers to an optical fiber 67 corresponding to a particular bore 37 "crossing" into a different bore 37 that does not correspond to that optical fiber.

[0031]

[0048] As shown, the tapered divider portion 49 has a first end 43 adjacent the bore 37 and a second end 53 proximate the rear end 21, with a tapered surface 55 diverging from the first end 43 to the second end 53. The tapered divider portion 49 has a cross-sectional shape at the first end 43 that is coaxial with the longitudinal axis L1 of the bore 37. Stated another way, the cross-section of the first end 43 of the tapered divider portion 49 extends around the periphery of the bore 37 and is coaxial with the bore 37. In some embodiments, the cross-sectional shape of the first end 43 of the tapered divider portion 49 is circular, and the cross-section is coaxial with the bore 37. However, it is within the scope of this disclosure that alternative suitable cross-sectional shapes may be used in alternative embodiments. In some embodiments, the tapered divider portion 49 has a length L2 that is less than 250 microns.

[0032]

[0049] As shown, the tapered divider portion 49 has a height H1 at the first end 43 that ranges from 100 microns to 250 microns, from 100 microns to 150 microns, or from 125 microns to 150 microns. The tapered divider portion 49 also has a width W1 at the first end 43 that ranges from 100 microns to 250 microns, from 100 microns to 150 microns, or from 100 microns to 125 microns. In some embodiments, the first end 43 of the tapered divider portion 49 is adjacent the bore 37 of the ferrule 16.

[0033]

[0050] The tapered divider portion 49 has a cross-sectional shape at its second end 53 that is coaxial with the longitudinal axis LI of the bore 37. Stated another way, the cross-section of the tapered divider portion 49 at its second end 53 extends around the bore 37 and is coaxial with the bore 37. In some embodiments, the cross-sectional shape of the tapered divider portion 49 at its second end 53 is rectangular, and the cross-section is coaxial with the bore 37. However, it is within the scope of this disclosure that alternative suitable cross-sectional shapes may be used in alternative embodiments. As shown, the tapered divider portion 49 has a height H2 at its second end 53 that is in the range of between 200 microns and 800 microns, between 200 microns and 500 microns, or between 200 microns and 250 microns. The tapered divider portion 49 also has a width W2 at its second end 53 that is in the range of between 150 microns and 350 microns. In some embodiments, the width W2 of the tapered divider portion 49 is equal to the pitch between the bores 37. As used herein, "pitch" refers to the distance from the center of one bore 37 to the center of another adjacent bore 37. In some embodiments, the second end 53 of the tapered divider portion 49 is within the lead-in section 35. In some embodiments, the second end 53 of the tapered divider portion 49 is flush with the rear end 21 of the ferrule 16.

[0034]

[0051] In some embodiments, the height ratio H2:H1 from the second end 53 to the first end 43 ranges from 1.2:1 to 3:1. In some embodiments, the width ratio W2:W1 from the second end 53 to the first end 43 ranges from 1.2:1 to 3:1.

[0035]

[0052] As previously mentioned, tapered surface 55 is provided between first end 43 and second end 53 of tapered divider section 49. Tapered surface 55 connects first end 43 to second end 53 of tapered divider section 49, and tapered surface 55 is angled with respect to longitudinal axis LI of bore 37 and configured to guide an inserted optical fiber into bore 37. Specifically, when optical fiber 67 is inserted through second end 53 of tapered divider section 49, optical fiber 67 may be off-center with respect to the corresponding center C of bore 37 and contact one of tapered surfaces 55. Tapered surface 55 then guides optical fiber 67 into bore 37, allowing optical fiber 67 to continue advancing within bore 37. In some embodiments, tapered surface 55 has an angle θ ranging from 15° to 45°. Having an angled tapered surface as shown provides the advantage of softer vertical walls that guide an optical fiber 67 that is off-center relative to the center C of the bore 37 into alignment as it is advanced through the ferrule 16. This configuration facilitates insertion of the optical fiber into the bore 37 and improves installation time as the optical fiber is oriented into the bore 37. This contrasts with previous ferrule configurations that have vertical walls that are generally perpendicular to the longitudinal axis LI. Such vertical walls provide a hard stop for the optical fiber 67 that can contact and damage the inserted optical fiber 67 or interfere with the installation of the optical fiber 67, increasing installation time.

[0036]

[0053] As discussed below, the tapered surface 55 is further configured to prevent lateral misalignment of the optical fiber. Stated differently, the tapered surface 55 provides a physical barrier for the inserted optical fiber, preventing the optical fiber from crossing into an incompatible bore 37. This feature of the tapered surface 55 allows for precise positioning of the optical fiber 67 relative to the corresponding bore 37 in the ferrule 16.

[0037]

[0054] Specifically, adjacent tapered divider sections 49 have corresponding adjacent tapered surfaces 55 that converge to form an edge 56 at the second end 53, as shown in FIG. 5 . The edges 56 are configured to prevent lateral misalignment of the optical fiber 67 into a mismatched bore. In other words, the edges 56 are configured to prevent crossover of the optical fiber. The edges 56 also enable passive lateral optical fiber insertion into the corresponding bore, whereby an optical fiber 67 that is misaligned with the corresponding bore 37 can contact the edges 56 and the corresponding tapered surfaces 55, and the optical fiber 67 is guided into the corresponding bore 37. In some embodiments, the edges 56 can be sharp edges that converge such that the tapered surfaces 55 form a straight edge. In some embodiments, the edges 56 can be rounded edges that converge such that the tapered surfaces 55 form a rounded edge having a radius of curvature.

[0038]

[0055] Referring now to FIG. 7, an alternative embodiment of a ferrule 16 is shown. As shown, the ferrule 16 has a single row of bores 37 that are coplanar with one another and include the tapered divider portions 49 described above. The ferrule 16 also includes a window 63 in the ferrule body 17. Specifically, the window 63 is located on the top side of the ferrule body 17. However, in an alternative embodiment, the window 63 is located on the bottom side of the ferrule body 17. In an alternative embodiment, the window 63 is located on both the top and bottom sides of the ferrule body 17, as shown in FIG. 7B. The window 63 provides access to the inserted optical fiber, allowing an operator to visually inspect the inserted optical fiber to ensure that the corresponding optical fiber 67 is oriented into the corresponding bore 37. Additionally, the window 63 provides access to the interior of the ferrule 16 so that a binder can be inserted into the ferrule 16 and the bores 37 during optical fiber insertion, as described below. The binder 65 is configured to couple the optical fiber 67 within the ferrule 16 to form the connector assembly.

[0039]

[0056] 7A-7C, various embodiments for depositing a binder 65 on the ferrule 16 and / or lead-in section 35 are shown. Referring first to FIG. 7A, the binder 65 is injected through the lead-in section 35 and into the bore 37 and microholes 25. As shown, the binder 65 seats substantially the entire length of the bore 37 and microholes 25, with a portion of the binder 65 seating beyond the rear end of the bore 37 and into the tapered divider section 49. When the optical fiber 67 is inserted into the lead-in section 35, the tapered divider section 49, and the bore 37, the optical fiber 67 is inserted through the ferrule 16 and the binder 65. Referring to FIG. 7B, in another embodiment, the binder 65 is injected through the window 63 of the ferrule 16, with the binder 65 seating adjacent the second end 53 of the tapered divider section 49. In this embodiment, the optical fiber 67 is inserted through the lead-in section 35 and the binder 65 into the bore 37 with the binder 65 wrapped around the outer surface of the optical fiber 67. As shown in FIG. 7C, in another embodiment, the optical fiber 67 is inserted into the lead-in section 35 and the bore 37 of the ferrule 16 with the binder 65 wrapped around the outer surface of the optical fiber 67. FIGS. 7A-7C are illustrative examples of how the binder 65 may be applied to the optical fiber 67 and within the ferrule 16. However, it is within the scope of this disclosure that alternative techniques for treating the ferrule to promote better adhesion between the optical fiber 67 and the ferrule 16, such as laser etching / laser treatment (e.g., plasma treatment), may be used.

[0040]

[0057] 8A and 8B, a method for inserting optical fiber ribbons 59, 61 into ferrule 16 is shown. Referring first to FIG. 8A, ferrule 16 is provided with spacers 39 separating two rows of bores 37, with spacers 39 being integrally formed with ferrule 16, as shown. However, spacers 39 are not flush with rear end 21 of ferrule 16 as shown. Rather, spacers 39 are located within lead-in section 35. Referring next to FIG. 8B, optical fiber ribbons 59 and 61 are inserted into lead-in section 35 so as to align with the two rows of bores 37. To do so, the distal optical fibers of optical fiber ribbons 59, 61 are aligned with indicia 51 at the rear end of ferrule 16 to ensure proper fiber alignment between the distal fibers of optical fiber ribbons 59, 61 and the corresponding bores 37. As shown, the spacers 39 within the lead-in section 35 allow the optical fiber ribbons 59, 61 to be inserted into the lead-in section 35 with the optical fiber spacers 57 disposed between the optical fiber ribbons 59, 61. The optical fiber spacers 57 are configured to align with the spacers 39 of the ferrule 16 so that the optical fiber ribbons 59, 61, which may have optical fiber misalignment between groups (i.e., optical fibers 67 for the bores 37 of a first group 27 being inserted into the bores 37 of a second group 29), can be aligned with the first and second groups 27, 29 of the bores 37, respectively. The optical fiber ribbons 59, 61 then engage the corresponding tapered divider portions 49 as they are inserted into the lead-in section 35, which guide the optical fibers of the optical fiber ribbons 59, 61 into the corresponding bores 37. The optical fibers of the optical fiber ribbons 59, 61 are then advanced through the bores 37 and through the microholes 25 to the front end 19 of the ferrule 16.

[0041]

[0058] 9A and 9B, an alternative method of inserting optical fiber ribbons 59, 61 into ferrule 16 is shown. Referring first to FIG. 9A, ferrule 16 is provided with spacers 39 separating two rows of bores 37, as shown. Spacers 39 are integrally formed with ferrule 16 and are flush with rear end 21 of ferrule 16. Referring next to FIG. 9B, optical fiber ribbons 59, 61 are inserted into their respective openings 47 so that optical fiber ribbons 59 and 61 correspond with first and second groups 27, 29 of bores 37, as shown. To do so, the distal optical fibers of optical fiber ribbons 59, 61 are aligned with indicia 51 at the rear end of ferrule 16 to ensure proper fiber alignment between the distal fibers of optical fiber ribbons 59, 61 and the corresponding bores 37. The optical fiber ribbons 59, 61 are then inserted into the lead-in section 35, engaging the corresponding tapered divider portions 49, which guide the optical fibers of the optical fiber ribbons 59, 61 into the corresponding bores 37. The optical fibers of the optical fiber ribbons 59, 61 are then advanced through the bores 37 and through the microholes 25 to the front end 19 of the ferrule 16.

[0042]

[0059] In some embodiments, the described ferrule 16 is not sized for use as an MPO connector ferrule. In other words, the ferrule 16 is shorter and / or thinner than a standard ferrule for an MPO connector, which may render the ferrule 16 incompatible with devices designed for conventional MPO connectors. To address this issue, a converter 80 is coupled to the ferrule 16 so that the form factor of the resulting assembly is equivalent to a conventional MT ferrule for an MPO connector. While the above description refers to an MPO connector, it is within the scope of this disclosure that the concepts may be used for other suitable connector applications.

[0043]

[0060] 10-13, there is shown a ferrule assembly 70. The ferrule assembly 70 includes the ferrule 16 described above and a converter 80. As shown, the converter 80 includes a front end 81, a rear end 83, and a converter body 85.

[0044]

[0061] The converter body 85 includes an opening 87 defined by the converter body 85 and extending between the front end 81 and the rear end 83. The opening 87 is configured to receive the ferrule 16 within the converter body 85 between the front end 81 and the rear end 83. The converter body 85 further includes a locking wedge 89 and side surfaces 91, 92 extending from upper and lower sections 93, 95 of the converter body 85 into the opening 87. The locking wedge 89 and side surfaces 91, 92 cooperate to retain the ferrule 16 within the converter 80.

[0045]

[0062] Locking wedge 89 is configured to engage ledge A and extend into recessed portion 28 when coupling ferrule 16 to converter 80. Specifically, to secure ferrule 16 to converter 80, ferrule 16 is advanced in direction A1 with rear end 21 first advanced into opening 87. Continued advancement of ferrule 16 in direction A1 eventually advances ledge A beyond locking wedge 85 (toward rear end 83 of converter 85). At this point, locking wedge 89 extends into recessed portion 28 of ferrule 16, and vertical surface 90 of locking wedge 89 engages ledge A to hold ferrule 16 in place and restrict movement in the Z direction, as defined by the Cartesian coordinate system of the figure.

[0046]

[0063] As previously described, the locking wedge 89 and the side surfaces 91, 92 cooperate to retain the ferrule within the converter 80. Specifically, the side surfaces 91, 92 extend from the front end 81 of the converter 80 toward the rear end 83 of the converter 80. The side surfaces 91, 92 include corresponding surfaces 91A, 92A, respectively, configured to correspond to the beveled edges 71, 72 of the ferrule 16, with the surfaces 91A, 92A spaced apart from one another by a width W, which corresponds to the width of the ferrule 16. As shown, the surfaces 91A, 92A are angled relative to the longitudinal axis L such that the angle of the surfaces 91A, 92A is the same as the angle of the beveled edges 71, 72 relative to the longitudinal axis L. Side surfaces 91, 92 are at the same angle and spaced apart by a width W to accommodate insertion of ferrule 16 into converter 80 along direction A1, so that surfaces 91A, 92A contact beveled edges 71, 72 of ferrule 16 and apply a force to the inserted ferrule 16. Thus, side surfaces 91, 92 apply a force in the XY plane that, in cooperation with the physical structure of converter 80, restricts movement of ferrule 16 in the XY plane, as defined by the Cartesian coordinate system of the figure.

[0047]

[0064] 11 , when the ferrule 16 is inserted into the converter 80, the end face 30 of the ferrule 16 may protrude outward from the front end 81 of the converter 80. Advantageously, such outward protrusion allows for polishing of the inserted optical fiber 67 and the end face 30 without affecting the converter 80. Polishing the end face 30 may aid in achieving physical contact between the inserted optical fiber 67 of the mating connector 10 by modifying the geometry of the end face 30 to increase the angle between the end face 30 and the inserted optical fiber 67. In alternative embodiments, it is within the scope of this disclosure that the ferrule 16 may be recessed within the converter 80 or that the end face 30 of the ferrule 16 may be flush with the front end 81 of the converter 80.

[0048]

[0065] Converter 80 further includes pinholes 93, 95 that correspond to pinholes 31, 33 of ferrule 16 when ferrule 16 is inserted into converter 80. Pinholes 93, 95 are configured to align with pinholes 31, 33 of ferrule 16 and extend the length of pinholes 31, 33 to rear end 83 of converter 80. Thus, pinholes 31, 33 can receive guide pins when ferrule 16 is installed within converter 80 and connector 10.

[0049]

[0066] 13, there is shown a rear view of the ferrule assembly 70. As shown, the converter 80 further includes a lead-in portion 97 that extends from the rear end 83 of the converter 80 into the opening 87 of the converter 80. The lead-in portion 97 is configured to provide access to the rear end 21 of the ferrule 16 and the corresponding lead section 35 when the optical fiber 67 is inserted into the ferrule assembly 70.

[0050]

[0067] 10 , to secure the converter 80 to the ferrule 16, the ferrule 16 is first advanced along direction A1 within the opening 87 of the converter 80 so that the rear end 21 is close to the lead-in portion 97 of the converter 80. As the ferrule 16 is advanced along direction A1, the ferrule 16 engages with the locking wedge portion 89 of the converter 80. Specifically, a vertical surface 90 of the locking wedge portion 89 engages with the ledge A of the ferrule 16, and as a result, the ferrule 16 and the converter 80 are snap-fitted together to form the ferrule assembly 70.

[0051]

[0068] After assembly of the ferrule assembly 70, the optical fiber(s) 67 are inserted through the lead-in portion 97 of the converter 80 and into the corresponding bore 37 of the ferrule 16. In some embodiments, a bonding agent 65 may be applied before, during, or after insertion of the optical fiber(s) 67 into the ferrule assembly 70, as previously described with reference to Figures 7A-7C, to form the connector. Polishing of the connector 10 is then completed.

[0052]

[0069] In an alternative embodiment, to assemble connector 10, optical fiber(s) 67 are first inserted through lead-in section 97 of converter 80 and through opening 87 of converter 80A. A binder 65 is then applied into bore 37 of ferrule 16 using any of the methods discussed above with respect to FIGS. 7A-7C so that the inserted optical fiber(s) 67 are bonded to bore 37 of ferrule 16. After securing optical fiber 67 within bore 37, converter 80 is moved over ferrule 16, and converter 80 and ferrule 16 are snap-fit ​​engaged with one another as described above. In this embodiment, polishing of end face 30 of ferrule 16 can be completed before or after snap-fit ​​assembly of ferrule assembly 70.

[0053]

[0070] 14-16, there is shown an alternative embodiment of the ferrule assembly 70. In describing the alternative embodiment of the ferrule assembly 70, like components of the ferrule assembly 70 between the embodiments are numbered the same except as noted herein. In this embodiment, the ferrule assembly 70 includes the ferrule 16 described above and a converter 80A.

[0054]

[0071] Converter 80A includes a front end 81, a rear end 83, and a converter body 85 extending from front end 81 to rear end 83. Converter body 85 includes an opening 87 extending between front end 81 and rear end 83 and defined by the shape of converter body 85. Opening 87 is configured to receive ferrule 16 within converter body 85 between front end 81 and rear end 83. Converter body 85 further includes a locking wedge 89 and side surfaces 91, 92 extending from upper and lower sections 93, 95 of converter body 85 into opening 87. Locking wedge 89 and side surfaces 91, 92 cooperate to retain ferrule 16 within converter 80.

[0055]

[0072] The locking wedge 89 is configured to engage ledge A and extend into the recessed portion 28 when the ferrule 16 is coupled to the converter 80. Specifically, a vertical surface 90 of the locking wedge 89 engages ledge A to hold the ferrule 16 in place and restrict movement in the Z direction, as defined in the Cartesian coordinate system of the illustration. Additionally, as shown, the converter 80A further includes a second locking wedge 98 that contacts the rear end 21 of the ferrule 16. Specifically, the second locking wedge 98 includes a vertical surface 99 that contacts the rear end 21 of the ferrule 16. Thus, the second locking wedge 98 engages the rear end 21 of the ferrule 16 to hold the ferrule 16 in place and restrict movement in the Z direction, as defined in the Cartesian coordinate system of the illustration. Although the second locking wedge 98 is shown in Figures 15 and 16, it is within the scope of this disclosure that in alternative embodiments, the second locking wedge 98 may be omitted and an auxiliary structure or structures of the overmolded converter 80A (e.g., additional material surrounding the pinholes 93, 95) may contact the rear end 21 of the ferrule 16 to help hold the ferrule 16 in place within the converter 80A.

[0056]

[0073] To further secure the ferrule within the converter 80A, side surfaces 91 and 92 extend from the front end 81 of the converter 80 toward the rear end 83 of the converter 80. The side surfaces 91 and 92 include corresponding surfaces 91A and 92A, respectively, configured to mate with the beveled edges 71 and 72 of the ferrule 16, as discussed below. Additionally, the surfaces 91A and 92A are spaced apart from one another by a width corresponding to the width of the ferrule 16. As shown, the surfaces 91A and 92A are angled relative to the longitudinal axis L such that the angles of the surfaces 91A and 92A relative to the longitudinal axis L are the same as the angles of the beveled edges 71 and 72. The side surfaces 91 and 92 have the same angle and are spaced apart by the width W of the ferrule 16, allowing the surfaces 91A and 92A to conform to the ferrule 16 being inserted into the converter 80A, such that the surfaces 91A and 92A contact the beveled edges 71 and 72 of the ferrule 16 and apply a force to the inserted ferrule 16. Thus, the side surfaces 91, 92 apply an XY plane force which, in cooperation with the physical structure of the converter 80A, restricts movement of the ferrule 16 within the XY plane defined by the Cartesian coordinate system of the figure.

[0057]

[0074] 15 , when the ferrule 16 is surrounded by the converter 80A, the end face 30 of the ferrule 16 may protrude outward from the front end 81 of the converter 80A. Advantageously, such outward protrusion allows for polishing of the inserted optical fiber 67 and the end face 30 without affecting the converter 80A. Polishing the end face 30 may aid in achieving physical contact between the inserted optical fiber 67 of the mating connector 10 by modifying the geometry of the end face 30 to increase the angle between the end face 30 and the inserted optical fiber 67. In alternative embodiments, it is within the scope of this disclosure that the end face 30 of the ferrule 16 may be recessed within the converter 80A or that the end face 30 of the ferrule 16 may be flush with the front end 81 of the converter 80A.

[0058]

[0075] Converter 80A further includes pinholes 93, 95 that correspond to pinholes 31, 33 of ferrule 16 when ferrule 16 is inserted into converter 80A. Pinholes 93, 95 are configured to align with pinholes 31, 33 of ferrule 16 and extend the length of pinholes 31, 33 to rear end 83 of converter 80A. Thus, pinholes 31, 33 can receive guide pins when ferrule 16 is installed within converter 80A and connector 10.

[0059]

[0076] 16, there is shown a rear view of the ferrule assembly 70. As shown, the converter 80A further includes a lead-in portion 97 that extends from the rear end 83 of the converter 80A into the opening 87 of the converter 80A. The lead-in portion 97 is configured to provide access to the rear end 21 of the ferrule 16 and the corresponding lead-in section 35 when the optical fiber 67 is inserted into the ferrule assembly 70.

[0060]

[0077] To apply the converter 80A onto the ferrule 16, the converter 80A is overmolded onto the ferrule 16. In some embodiments, the converter 80A is molded directly onto the ferrule 16 in a molding operation. Advantageously, by molding the converter 80A onto the ferrule 16, features of the ferrule 16 create a cohesive geometry / configuration that keeps the ferrule 16 and the converter 80A coupled to one another throughout their respective lifetimes. For example, the location of the ledge A and the recessed portion 28 of the ferrule 16 create a geometry of the converter 80A that allows the converter 80A to couple to the ferrule 16.

[0061]

[0078] Since these and other variations, modifications, combinations, and subcombinations of the disclosed embodiments may occur to those skilled in the art, the present invention is to be construed as including all within the scope of the appended claims and their equivalents. [Explanation of symbols]

[0062] 10 Optical Fiber Connector 12 Fiber optic cable 14 Optical fiber cable assembly 16 ferrules 17 Ferrule body 18 Housing 19 Ferrule front end 20 Slider 21 Rear end of ferrule 22 Boots 23 Ferrule end face 24 Front part of ferrule 25 ferrule holes, micro holes 26 Front end of housing 27, 29 Microhole group, bore group 28 Recessed area 30 Ferrule end face 31, 33 Pinhole 32 Upper surface of ferrule 34 Guide pin assembly 35 Lead-in section 36 Spring 37 bore 38 Crimp body 39 Spacer 40 Crimp Ring 42 Rear part of ferrule 43 first end of tapered divider portion 44 Guide pin 45 channels 46 Pinkie Pie 47 Aperture 49 Tapered divider section 50 Latch Arm 51 displays 52 Recessed portion in housing 53 second end of tapered divider portion 54 End part 55 Tapered surface of tapered divider section 56 Edge 57 Fiber Spacer 59, 61 Optical fiber ribbon 63 Window 65 Binder 67 Optical Fiber 70 Ferrule assembly 71, 72 Beveled edge of ferrule 80, 80A converter 81 Front end of converter 83 Rear end of converter 85 Converter body 87 Opening 89 Fixing wedge 90 Vertical Surfaces 91, 92 Lateral surface 91A, 92A Surface corresponding to the beveled edge of the ferrule 93, 95 Pinhole 93 Upper division 95 Lower division 97 Lead-in section 98 Second fixing wedge 99 Vertical Surfaces A Ledge A1 Insertion direction into converter BS ferrule bottom surface C Center of bore H1 Height of the first end of the tapered ferrule H2 Height of the second end of the tapered ferrule L longitudinal axis L1 Longitudinal axis of the bore L2 Length of tapered divider P1, P2 Plane where groups of microholes exist TS ferrule top surface W1 Width of the first end of the tapered ferrule W2 Width of the second end of the tapered ferrule θ Angle of the tapered surface

Claims

1. 1. A ferrule for an optical connector configured to receive a plurality of optical fibers, said ferrule comprising: a body having a front end and a rear end, the body extending longitudinally between the front end and the rear end; a plurality of bores extending into the body from the front end toward the rear end, each bore configured to receive one of the plurality of optical fibers; A plurality of tapered divider sections, each tapered divider section comprising: a first end adjacent each of the plurality of bores and a second end adjacent the rear end of the ferrule; a cross-sectional shape of the first end extending around each of the plurality of bores such that the bores are separated from one another; and a plurality of tapered divider sections having a tapered surface from the second end to the first end; The ferrule is provided.

2. 2. The ferrule according to claim 1, A ferrule, wherein the rear end of the ferrule includes indicia whereby the indicia provide a visual indicator of horizontal alignment of the optical fibers within the bores of the ferrule.

3. 3. The ferrule according to claim 2, The indicia extend from the rear end of the ferrule to the second end of the tapered divider portion.

4. The ferrule according to any one of claims 1 to 3, The ferrule, wherein the tapered divider portion has a height H1 at a first end and a height H2 at the second end, wherein the height ratio H2:H1 is in the range of 1.2:1 to 3:

1.

5. The ferrule according to any one of claims 1 to 4, The ferrule, wherein the tapered divider portion has a width W1 at a first end and a width W2 at the second end, wherein the width ratio W2:W1 is in the range of 1.2:1 to 3:

1.

6. The ferrule according to any one of claims 1 to 5, The ferrule, wherein the tapered divider portion has a circular cross section at the first end and a square cross section at the second end.

7. The ferrule according to any one of claims 1 to 6, The ferrule wherein the tapered surface of the tapered divider portion has an angle in the range of 15° to 45° relative to a longitudinal axis of one of the bores.

8. The ferrule according to any one of claims 1 to 7, A ferrule, wherein adjacent tapered divider sections have corresponding adjacent tapered surfaces forming edges, said edges configured to prevent insertion of an optical fiber into an incompatible bore.

9. The ferrule according to any one of claims 1 to 8, the second end of the tapered divider portion is flush with the rear end of the ferrule.

10. The ferrule according to any one of claims 1 to 9, the plurality of bores comprises a first row of bores and a second row of bores spaced apart from the first row of bores, the bores in the first row being coplanar with one another and the bores in the second row being coplanar with one another.

11. The ferrule according to claim 10, The first row of bores and the second row of bores are separated by a spacer that is flush with the rear end of the ferrule, the spacer being integrally formed with the ferrule.

12. The ferrule according to any one of claims 1 to 11, The ferrule further comprises a window formed in a top or bottom surface of the ferrule, the window extending into a lead-in section of the ferrule adjacent the tapered divider portion.

13. An optical connector, A ferrule according to any one of claims 1 to 12; a plurality of optical fibers secured to the ferrule, each optical fiber extending from the rear end of the body into one of the microholes; An optical connector comprising:

14. 14. The optical connector according to claim 13, the plurality of bores comprises a first row of bores and a second row of bores spaced apart from the first row of bores; the first row of bores are coplanar with one another and the second row of bores are coplanar with one another; the plurality of optical fibers comprises a first ribbon of optical fibers and a second ribbon of optical fibers; the first ribbon of optical fibers and the second ribbon of optical fibers are coplanar with one another; the first ribbon of optical fibers and the second ribbon of optical fibers are separated by an optical fiber spacer; the first ribbon of optical fibers, the second ribbon of optical fibers, and the optical fiber spacers are inserted into the rear end of the ferrule such that the first ribbon of optical fibers is inserted into the first row of bores and the second ribbon of optical fibers is inserted into the second row of bores.

15. 15. The optical connector according to claim 14, an optical connector, wherein the first row of bores and the second row of bores are separated by a spacer that is flush with the rear end of the ferrule, the spacer being integrally formed with the ferrule;

16. 16. The optical connector according to claim 15, the plurality of optical fibers comprises a first ribbon of optical fibers and a second ribbon of optical fibers, the first ribbon of optical fibers and the second ribbon of optical fibers being coplanar with one another; the first ribbon of optical fibers and the second ribbon of optical fibers are inserted into the rear end of the ferrule such that the first ribbon of optical fibers is inserted into a first row of bores and the second ribbon of optical fibers is inserted into a second row of bores.

17. 17. A method of terminating a plurality of optical fibers using a ferrule according to any one of claims 1 to 16, comprising the steps of: aligning the optical fiber with the bore of the ferrule; extending the optical fibers through the rear end of the ferrule and into the bores, wherein the tapered divider section allows one optical fiber to extend through each of the bores.

18. 18. The method of claim 17, The aligning step comprises: aligning a first ribbon of optical fibers with a first row of bores; and aligning a second ribbon of optical fibers with the second row of bores.

19. 20. The method of claim 18, aligning the first ribbon of optical fibers includes aligning optical fibers of the first ribbon with indicia on the rear end of the ferrule; The method, wherein aligning the second ribbon of optical fibers includes aligning optical fibers of the second ribbon with the indicia on the rear end of the ferrule.

20. 20. The method of claim 18 or 19, the first ribbon of optical fibers and the second ribbon of optical fibers are separated by an optical fiber spacer that is inserted into the ferrule along with the first ribbon of optical fibers and the second ribbon of optical fibers.

21. 21. The method of any one of claims 17 to 20, comprising: The method further comprising the step of dispensing adhesive into the tapered divider portion.

22. 22. The method of claim 21, The method wherein the adhesive is supplied to the bore through a window formed in an upper surface of the ferrule and extending into a lead-in section of the ferrule adjacent the tapered divider portion.

Images