Optical Connector

Abstract

An optical connector is provided that includes one or more optical cables disposed within a housing. [Solution] An optical connector comprising: one or more optical cables, each optical cable having an array of at least one optical waveguide and at least one optical ferrule attached to the at least one optical waveguide; and a housing including one or more waveguide support walls, each waveguide support wall configured to allow insertion of the optical cable into the housing when the optical waveguides of the optical cable are in a substantially straight configuration, and each waveguide support wall having an inclined surface that supports the optical waveguide at a predetermined angle relative to the mating axis of the optical connector after the optical waveguide is bent within the housing.

Description

[Technical field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates generally to optical connector assemblies and methods relating to optical connector assemblies. [Background technology]

[0002] Optical connectors can be used for optical communication in a variety of applications, including telecommunication networks, local area networks, data center links, and internal links in computing devices. There is interest in extending optical communication to internal applications in smaller consumer electronics, such as laptop computers and even cell phones. In connectors for these systems, an expanded light beam can be used to achieve optical connections that are less susceptible to dust and other forms of contamination, thereby relaxing alignment tolerances. In general, an expanded beam is a beam that has a diameter larger than the core of the associated optical waveguide (usually an optical fiber, e.g., a multimode fiber for multimode communication systems). If it is an expanded beam at the connection point, it is generally considered to be an expanded beam connector. Expanded beams are usually obtained by diverging a light beam from a light source or optical fiber. In many cases, the diverging beam is processed by optical elements such as lenses or mirrors to become a nearly collimated expanded beam. The expanded beam is then received by focusing the beam by another lens or mirror. These expanded beam optical connectors can be non-contact optical couplings and require less mechanical precision compared to conventional optical connectors. Summary of the Invention

[0003] Some embodiments relate to an optical connector comprising one or more optical cables disposed within a housing. Each optical cable comprises at least one optical waveguide and at least one optical ferrule attached to the optical waveguide. The housing comprises a first housing portion and a second housing portion engaged with the first housing portion. The second housing portion comprises at least one carrier and a frame. The carrier and frame of the second housing portion are configured to support the one or more optical cables. The first housing portion and the second housing portion are configured such that mechanical engagement of the first housing portion and the second housing portion moves the carrier relative to the frame. Movement of the carrier relative to the frame causes bending of each optical waveguide and rotation of each ferrule. The bending provides a predetermined spring force of the optical waveguide at a predetermined angle of the ferrule.

[0004] According to some embodiments, the optical connector described above includes an actuator configured such that actuation of the actuator causes relative movement between the carrier and the frame, which causes bending of the optical waveguide and rotation of the ferrule.

[0005] Some embodiments relate to an optical connector comprising one or more optical cables and a housing. Each optical cable comprises at least one optical waveguide and at least one optical ferrule attached to the optical waveguide. The housing includes one or more waveguide support walls. Each waveguide support wall is configured to allow insertion of the optical cable into the housing when the waveguides of the optical cable are in a substantially straight configuration. Each waveguide support wall has an angled surface that supports the waveguide at an angle relative to a mating axis of the optical connector after the waveguide is bent within the housing.

[0006] According to some embodiments, an optical connector includes one or more optical cables, each optical cable comprising at least one optical waveguide and at least one optical ferrule attached to the optical waveguide. The optical cables are disposed within a housing of the connector. The housing includes one or more waveguide support walls configured to support the optical cables. The one or more waveguide support walls are configured to allow insertion of the optical cables into the housing along a direction substantially perpendicular to a mating axis of the optical connector.

[0007] Some embodiments relate to an optical cable. The optical cable includes at least one optical waveguide having a longitudinal axis. At least one optical ferrule is attached to the optical waveguide. A cable retainer is attached to the optical waveguide and spaced apart from the ferrule. The optical cable is configured such that when the optical waveguide is held by the cable retainer such that a portion of the optical waveguide in the cable retainer is horizontally straight with respect to gravity, a portion of the optical waveguide in the ferrule sags less than a predetermined percentage x% of a distance d between the cable retainer and the optical ferrule.

[0008] Some embodiments relate to a method of assembling an optical connector, comprising: inserting one or more optical cables into a housing comprising a carrier and a frame. Each optical cable comprises at least one optical waveguide and at least one optical ferrule attached to the optical waveguide. Activating an actuator that produces relative movement between the carrier and the frame. In response to the relative movement between the carrier and the frame, the optical waveguide bends and the ferrule rotates. The bending of the optical waveguide provides a predetermined spring force at a predetermined angle of the ferrule. [Brief description of the drawings]

[0009] [Figure 1A] 1 illustrates a partial see-through perspective view of a connector comprising a first housing portion and a second housing portion after engagement of the first housing portion and the second housing portion, according to some embodiments. [Figure 1B]1B shows a second housing portion of the connector of FIG. 1A. [Figure 1C] 1B is a perspective view of the connector of FIG. 1A during engagement of the first and second housing portions; [Figure 1D] 1B is a perspective view of the connector of FIG. 1A after engagement of the first and second housing portions of the connector of FIG. 1A. FIG. [Figure 1E] 1B illustrates the insertion of an optical cable into the second housing portion of the connector of FIG. 1A. [Figure 1F] 1B illustrates the insertion of an optical cable into the second housing portion of the connector of FIG. 1A. [Figure 1G] 1B illustrates the optical cable after engagement of the first and second housing portions of the connector of FIG. 1A. [Figure 2A] 1 illustrates an optical cable that can be used in an optical connector according to some embodiments. [Figure 2B] 2B illustrates the gravity-induced bending (sagging) of the optical cable of FIG. 2A when held horizontally and perpendicular to gravity. [Figure 2C] 1 illustrates an optical cable with one cable retainer attached to two sets of optical waveguides, each set of optical waveguides attached to a different ferrule, according to some embodiments. [Figure 2D] FIG. 13 is a cutaway view of a portion of a ferrule converging onto a light redirecting member of the ferrule, according to some embodiments. [Figure 2E] FIG. 1 illustrates a side view of two optical cables showing mating ferrules, according to some embodiments. [Figure 3A] 1 illustrates an optical connector having a monolithic carrier according to some embodiments. [Figure 3B] 3B shows a second housing portion of the connector of FIG. 3A. [Figure 4A] 1 is a perspective view of an optical connector according to some embodiments. [Figure 4B] 4B is a partial perspective view of the first and second housing portions of the connector of FIG. 4A. [Figure 5A]1 illustrates a partial perspective view of an optical connector according to some embodiments. [Figure 5B] 5B illustrates the operation of an actuator of the connector of FIG. 5A. [Figure 5C] 5B illustrates the operation of an actuator of the connector of FIG. 5A. [Figure 6] FIG. 1 is a flow diagram illustrating a method for introducing an optical connector, according to some embodiments. The figures are not necessarily to scale. Like numbers used in the figures refer to like components. However, it will be understood that the use of a number to refer to a component in a particular figure is not intended to limit the component in another figure bearing the same number. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] The optical connectors described herein include one or more optical cable assemblies disposed in a housing. The optical cable assembly may include one waveguide or an array of multiple parallel waveguides (typically 4, 8, or 12 or more parallel waveguides) attached to one or more optical ferrules. The optical connectors described herein include using an optical cable assembly having a bent waveguide. The bending of the waveguide provides a predetermined mating force to the optical ferrule. The assembly of an optical connector including a bent optical waveguide can be simplified if the optical waveguide is inserted into the housing in a substantially straight or less bent configuration and then the waveguide is bent or more bent within the housing after insertion. The embodiments described below include connectors in which one or more optical cables may be inserted into the connector housing in a substantially straight or less bent configuration. After insertion of the optical cable into the connector housing, the connector is configured by moving a first portion of the connector housing relative to a second portion or the connector housing. Moving the first portion of the connector housing relative to the second portion of the connector housing bends and / or twists the optical waveguide of the optical cable and rotates the optical ferrule attached to the optical waveguide, the bending of the optical waveguide providing a predetermined spring force for the optical waveguide at a predetermined angle of the ferrule.

[0011] 1A-1G illustrate various aspects and components of an optical connector 100, according to some embodiments. The connector 100 includes an optical cable 110 disposed within a housing 120 comprising a first housing portion 121 and a second housing portion 122 engaged with the first housing portion 121. FIG. 1B illustrates the second housing portion 122. FIG. 1A illustrates a partial see-through perspective view of the connector 100 comprising the first housing portion 121 and the second housing portion 122 after partial engagement.

[0012] One or more optical cables 110 are partially disposed within the housing 120. Each optical cable 110 includes a waveguide array 111 with one or more optical waveguides attached to at least one optical ferrule 112. The optical waveguides may be optical fibers, e.g., single mode or multimode fibers, or planar waveguides disposed on a substrate. The individual waveguides of the waveguide array 111 are typically optical fibers made of glass with a protective buffer coating. The multiple parallel waveguides of the waveguide array 111 may be surrounded by a jacket.

[0013] 1A and 1B, the optical connector 100 includes four optical cables 110, each optical cable assembly including a waveguide array 111 with one or more waveguides and an optical ferrule 112. The connector 100 is shown oriented with respect to three orthogonal axes, a longitudinal axis 196, a transverse axis 197, and a vertical axis 198, the names of the axes being used for convenience and not intended to imply any particular orientation of the connector in space. The optical cables 110 may generally extend in a direction along the mating axis 199 of the optical connector 100 or in a slightly oblique direction and may be stacked within the housing 120 of the optical connector 100 along a connector vertical axis 198 that is orthogonal to the mating axis 199.

[0014] 1B shows a second housing portion 122 configured to support one or more optical cables 110. The second housing portion 122 includes a frame 140 and one or more carriers 130 that support the optical cables 110. The one or more carriers 130 and the optical cables 110 are at least partially disposed within the frame 140. Although the connector 100 shown in FIG. 1B has a frame and a carrier 130 according to various embodiments, an optical connector may include a frame or multiple frames and / or a carrier or multiple carriers.

[0015] The view shown in FIG. 1B shows the second part 122 of the housing 120 before engagement with the first housing part 121. The second housing part 122 comprises a carrier 130 and a frame 140 configured to support the optical cable 100. In FIG. 1B, the optical cable 110 is inserted into the carrier 130 and the frame 140 in a substantially straight configuration. The first housing part 121 (see FIG. 1A) and the second housing part 122 (see FIG. 1A and FIG. 1B) are configured such that mechanical engagement between the first housing part 121 and the second housing part 122 moves the carrier 130 relative to the frame 140 along an axis 198. FIG. 1A shows a perspective view of the connector 100 including the first housing part 121 and the second housing part 122 after engagement. The movement of the carrier 130 relative to the frame 140 causes bending 111a of each optical waveguide of the waveguide array 111 and rotation of each ferrule 112. The bend 111 a provides a predetermined spring force for the optical waveguide array 111 at a predetermined angle of the ferrule 112 .

[0016] The connector 100 includes a plurality of optical cables 110, each of which includes at least one cable retainer 113. The cable retainer 113 is attached to the waveguide array 111 of the optical cables 110, for example by adhesive or friction grip, and is spaced from the ferrule 112. The second housing portion 122 includes a carrier 130 including at least one retainer mount 143 configured to receive the cable retainer 113. As shown in FIGS. 1A-1G, the carrier 130 of the second housing portion 122 may include a plurality of retainer mounts 143, each of which is configured to receive a corresponding cable retainer 113.

[0017] The relationship between the number of cable holders and the number of optical cables may be one to one, as shown in Figures 1A-1G. Alternatively, in some embodiments, the number of cable holders may be less than the number of optical cables. For example, as shown in Figure 2C, one cable holder 113c may be attached to two optical waveguide arrays 111c-1 and 111c-2, which are attached to different ferrules 112c-1 and 112c-2, according to some embodiments.

[0018] Referring again to the embodiment shown in FIGS. 1A-1E, the frame 140 includes one or more ferrule supports 150 (see FIG. 1E) disposed at the mating end 180 of the optical connector 100. The ferrule supports 150 are configured to support the ferrules 112 of the optical cable 110. The frame 140 includes one or more frame waveguide support walls 141 disposed between the mating end 180 of the optical connector 100 and the carrier 130. Each frame waveguide support wall 141 is configured to support a corresponding optical waveguide array 111. The waveguide array may include one or more waveguides. As shown in FIG. 1B, each frame waveguide support wall 141 includes an inclined portion 141a that supports the optical waveguide 111 such that the optical waveguide 111 forms a predetermined angle θ with respect to the mating axis 199 of the optical connector 100. The predetermined angle θ may be, for example, 15 to 25 degrees or about 18 degrees.

[0019] As best seen in FIG. 1A, the carrier 130 may also include one or more carrier waveguide support walls 131 disposed between the mating end 180 of the optical connector and the retainer mount 143. Each carrier waveguide support wall 131 is configured to support a corresponding optical waveguide array 111. Each carrier waveguide support wall 131 may include an angled surface 131a that supports the optical waveguide array 111 such that the optical waveguide array 111 forms a predetermined angle θ with respect to a mating axis 199 of the optical connector 100. The predetermined angle θ may be, for example, 15 to 25 degrees or about 18 degrees.

[0020] The connector 100 is assembled by first inserting the optical cable 110 into the carrier 130 and frame 140 of the second housing portion 122 in a substantially straight or less bent configuration. After insertion of the optical cable 110, the first housing portion 121 and the second housing portion 122 are engaged. In the embodiment shown in FIGS. 1A-1G, the engagement of the first housing portion 121 and the second housing portion 122 moves the carrier relative to the frame along axis 198. The relative movement of the carrier 130 and the frame 140 bends or flexes the optical waveguide array 111 and rotates the optical ferrule 112. FIG. 1C is a perspective view of the connector 100 during engagement of the first housing portion 121 and the second housing portion 122. FIG. 1D is a perspective view of the connector 100 after engagement of the first housing portion 121 and the second housing portion 122. Figures IE and IF show the insertion of the optical cable 110 into the second housing portion 122. Figure IG shows the optical cable 110 after engagement of the first housing portion 121 and the second housing portion 122.

[0021] As best seen in Figures 1E and 1F, prior to engagement of the first housing portion 121 with the second housing portion 122, the carrier 130 and frame 140 are adapted to allow the optical cable 110 to be installed in and subsequently removed from the carrier 130 and frame 140 without damaging the carrier 130 and frame 140 and / or the second housing portion 122 containing the optical cable 110. The optical cable 110 may be inserted into the carrier 130 and frame 140 while the waveguide array 111 of the optical cable 110 is substantially straight or slightly bent prior to engagement of the first housing portion 121 with the second housing portion 122. Assembly of the connector 100 includes configuring the connector. Configuring the connector includes the actions of bending or more bending the optical waveguide array 111 and rotating the optical ferrule 112. 1A-1G, construction of the connector occurs when the first and second housing portions are engaged. The engagement of the first and second housing portions moves the carrier 130 relative to the frame 140. The relative movement causes the waveguide array 111 to bend or bend more, as shown in FIG. 1G.

[0022] The optical cable 110 may be inserted into the carrier and frame along one or more insertion axes. With reference to Figures 1E and 1F, in some configurations, the optical cable 110 is inserted into the carrier 130 and frame 140 of the second housing portion 122 along at least a first insertion axis. In some configurations, the optical cable 110 is inserted into the carrier 130 and frame 140 of the second housing portion 122 along orthogonal first, second, and / or third insertion axes.

[0023] In the embodiment shown in Figures 1E and 1F, the optical cable assembly is inserted into the carrier 130 and frame 140 along first and second insertion axes that are orthogonal to one another. The first insertion axis, e.g., connector transverse axis 197, is substantially orthogonal to the mating axis 199 of the optical connector 100. The second insertion axis, e.g., connector longitudinal axis 196, is substantially parallel to the mating axis 199 and orthogonal to the transverse axis 197. As shown in Figure 1F, insertion of the optical cable 110 along the transverse axis 197 (first insertion axis) and the longitudinal axis 196 (second insertion axis) inserts the ferrule 112 of the optical cable 110 between the ferrule supports 150 of the frame 140 and inserts the cable retainer 113 into the retainer mount 143 of the carrier 130.

[0024] In the embodiment shown in Figures 1A-1G, the first and second housing portions 121, 122 are engaged after the optical cable 110 is inserted into the second connector housing portion 122. Installation of the optical cable 110 involves insertion of the optical cable 110 along the transverse and longitudinal axes 197, 196 (first and second insertion axes), as described above. As shown in Figures 1C and 1D, engagement of the first and second housing portions 121, 122 involves relative movement between the first and second housing portions 121, 122 along at least the first engagement axis. As shown in Figure 1C, engagement of the first and second housing portions may, in some embodiments, involve movement along a transverse axis 197 that is substantially perpendicular to the mating axis 199. As further shown in FIG. 1C, in some embodiments, the mechanical engagement between the first housing portion 121 and the second housing portion 122 may involve relative rotational movement of the first housing portion 121 and the second housing portion 122. For example, the rotational movement may involve rotation about a rotation axis 198a (see FIG. 1C) that is substantially parallel to the axis 198. The rotation axis 198a may be substantially orthogonal to the mating axis 199, as shown in FIG. 1C. In other embodiments, the rotation axis may be substantially parallel to the mating axis 199, for example.

[0025] In the connector shown in Figures 1A-1G, the first and second housing portions 121, 122 are configured such that mechanical engagement between the first and second housing portions 121, 122 (see Figures 1C and 1G) causes the carrier 130 to move relative to the frame 140 along a configuration axis, e.g., a connector vertical axis 198, as shown in Figure 1G. In the embodiment shown in Figures 1E-1G, the axis 198 (configuration axis) is substantially perpendicular to the mating axis 199 of the optical connector 100 and is also substantially perpendicular to the horizontal axis 197. Movement of the carrier 130 relative to the frame 140 along the vertical (configuration) axis 198 causes the waveguide array 111 of the optical cable 110 to bend or twist from an initial position after insertion and rotates the ferrules 112 attached to the waveguide array 111.

[0026] FIG. 2A illustrates an optical cable 110 that can be used in an optical connector, according to some embodiments. The optical cable 110 includes one or an array of optical waveguides 111 extending along a waveguide longitudinal axis 195. At least one optical ferrule 112 is attached to each optical waveguide array 111, and a cable holder 113 is attached to the optical waveguide array 111 spaced apart from the ferrules 112. As illustrated in FIG. 2B, when the optical cable 110 is supported and held by the cable holder 113 in a straight horizontal direction against gravity, the optical waveguides 111 sag from the horizontal by less than a predetermined percentage x% of the distance d between the cable holder 113 and the optical ferrule 112. A suitable value of x% can range from about 20% to about 1%. For example, the value of x% can be about 20%, about 10%, about 5%, or about 1%. The distance d can be about 4 cm or about 1.8 cm in some embodiments. Additional information regarding cable retainers and retainer mounts, as well as optical connectors incorporating the retainers and mounts, is discussed in commonly assigned U.S. Patent No. 62 / 240008, identified by attorney docket number 76662US002, filed October 12, 2015, which is incorporated herein by reference. As previously mentioned, the optical waveguide array 111 may include an optical fiber or multiple optical fibers. At least one optical waveguide array 111 may include at least one planar waveguide disposed on a substrate, or multiple planar waveguides disposed on a substrate. The term optical waveguide is used herein to refer to an optical element that propagates signal light. An optical waveguide comprises at least one core having a cladding, the core and cladding being configured to propagate light, for example, by total internal reflection. The optical waveguide may be, for example, a single mode or multimode waveguide, a single-core fiber, a multi-core optical fiber, or a polymeric waveguide. The waveguide may have any suitable cross-sectional shape, for example circular, square, rectangular, etc.

[0027] The ferrule 112 is configured to mate (e.g., hermaphroditically) with another ferrule. The ferrule 112 shown in Figures 2A and 2B includes a mechanical mating tongue 116 and a light redirecting member 115. In some embodiments, the mechanical mating tongue 116 may have a tapered width along at least a portion of the length of its tongue portion, as shown. The mechanical mating tongue 116 may extend outwardly from a front surface of the connector housing (not shown in Figures 2A and 2B).

[0028] In some embodiments, multiple waveguide arrays may be attached to a single cable retainer. Figure 2C shows a cable retainer 113c attached to multiple waveguide arrays 111c-1, 111c-2, which are shown extending along a waveguide longitudinal axis 195. Figure 2C shows a first waveguide array 111c-1 attached to a ferrule 112c-1 and a second waveguide array 111c-2 attached to a second ferrule 112c-2. Each of the first and second waveguide arrays 111c-1, 111c-2 are attached to a single cable retainer 113c.

[0029] FIG. 2D is a cutaway view of a portion of the ferrule 112 focusing onto the light redirecting member. FIG. 2D illustrates the attachment of several light guides or waveguide arrays 111 to the ferrule portion 220. The light guides 111 are aligned within the grooves 108 where they will be permanently attached. At the attachment point, the fiber buffer coating and protective jacket (if present) of the waveguides 111 are stripped away, allowing only the bare optical fiber to be aligned and placed into the grooves 108 and permanently attached thereto. The output ends of the light guides in the array 111 are positioned such that light exiting each light guide in the light guide array 111 can be directed to the input side or input face of the corresponding light redirecting member 115. The ferrule portion 220 includes an array of light redirecting elements 117, at least one for each light guide in the waveguide array 111, attached to the ferrule 112. For example, in various embodiments, each light redirecting element 115 includes one or more of a prism, a lens, and a reflective surface. The ferrule portion 220 includes an array of light redirecting elements 117, one for each light guide in the light guide (fiber optic) array 111.

[0030] FIG. 2E shows a side view of two optical cables 110-1 and 110-2 having optical coupling members 115-1 and 115-2 and showing mating ferrules 112-1, 112-2 attached to the optical waveguide arrays 111-1, 111-2 at the optical coupling unit attachment areas 118-1, 118-2. Cable retainers 113-1, 113-2 are attached to the optical waveguide arrays 111-1, 111-2. The ferrules 112-1, 112-2 can be oriented at a predetermined mating angle α with respect to the mating direction. The bend of the optical waveguide arrays 111-1, 111-2 between the optical coupling unit attachment areas 118-1, 118-2 and the cable retainers 113-1, 113-2 provides a predetermined amount of spring force to maintain the ferrules 112-1, 112-2 in the mated position.

[0031] Further information regarding the features and operation of optical coupling units, optical cables, and optical connectors is discussed in commonly assigned U.S. Patent No. 61 / 710,077, filed October 5, 2012, which is incorporated by reference in its entirety.

[0032] Figures 3A and 3B show an optical connector 300 that is similar in many respects to the optical connector 100 shown in Figures 1A-1G. The optical connector 300 differs from the connector 100 in that the connector 300 includes a monolithic carrier 330 and does not include a separate cable retainer and retainer mount as shown in Figures 1A-1G. The monolithic carrier 330 may be attached directly to the waveguide array 111, for example, by adhesive or friction grip.

[0033] The connectors 100 and 300 shown in Figures 1A-1G and 3A-3B each include an actuator 170 that configures the connector after an optical cable assembly is inserted into the housing. Operation of the actuator 170 causes relative movement between the carrier 130, 330 and the frame 140 along an axis 198 (configuration axis). The relative movement between the carrier 130, 330 and the frame 140 along the axis 198 causes bending 111a of the waveguide array 111 of the optical cable 110, causing the ferrule 112 to rotate. The bending 111a of the waveguide array 111 provides a predetermined approximate spring force of the waveguide array 111 at a predetermined angle of the ferrule 112 relative to the mating axis 199 of the connectors 100, 300.

[0034] According to some implementations, the actuator 170 is configured such that movement of the actuator 170 occurs upon mechanical engagement of the first housing portion 121 and the second housing portion 122. As best seen in FIGS. 1A-1C, in some embodiments, the actuator 170 comprises an actuator rib 171 of the first housing portion 121 and a carrier surface 172 of the carrier 130. The actuator rib 171 comprises a first rib surface 171a and an angled rib surface 171b. The carrier surface 172 comprises a first carrier surface 172a and an angled carrier surface 172b. The angled surface of the rib 171b is complementary to the angled actuator surface 172b. When the connector 100 is oriented as shown in FIG. 1A, the surfaces 171a, 171b of the rib 171 are configured to interact with the actuator surfaces 172a, 172b. Surfaces 171a, 171b exert a force on surfaces 172a, 172b urging carrier 130 up along axis 198 (the configuration axis) relative to frame 140.

[0035] 1A, the second housing portion 122 may include a retaining clip 182 having an angled surface 182a. The retaining clip 182 is configured to engage with a mating feature 183 of the first housing portion 121. The engagement of the retaining clip 182 with the mating feature 183 holds the first housing portion 121 and the second housing portion 122 together after the first housing portion 121 and the second housing portion 122 are fully engaged.

[0036] FIG. 4A is a perspective transparent view of the housing 420 showing the first housing portion 421 and the second housing portion 422 fully engaged. FIG. 4B is an exploded perspective view of the connector 400 with the housing 420 including the first housing portion 421 and the second housing portion 422. The second housing portion 422 includes a carrier 430 and a frame 440, which are configured to move relative to one another during mechanical engagement of the first housing portion 421 and the second housing portion 422. The carrier 430 includes one or more retainer mounts 443 configured to receive a cable retainer of an optical cable, as previously described. As shown in FIGS. 4A and 4B, the frame 440 includes one or more ferrule supports 450 disposed at the mating end 480 of the optical connector 400. The ferrule support 450 is configured to support a ferrule 412 of an optical cable disposed within the connector housing 420, as previously described. The connector 400 includes an actuator 470 that, when actuated by engagement of the first housing portion 421 and the second housing portion 422, causes relative movement between the carrier 430 and the frame 440. As shown in Figures 4A and 4B, the actuator 470 comprises a tapered surface 471 of the first housing portion 421 configured to engage a surface 472 of the carrier 430. The engagement of the tapered surface 471 of the first housing portion 421 with the surface 472 of the carrier 430 moves the carrier 430 relative to the frame 440 along axis 198 (the configuration axis).

[0037] Engagement of the first housing portion 421 and the second housing portion 422 includes inserting the second housing portion into the cavity 420a of the first housing portion 421 through the opening 420b of the first housing portion 421. During engagement of the first and second housing portions 421, 422, the second housing portion 422 engages the first housing portion 421 along a longitudinal axis 196 that is substantially parallel to the mating axis 199. Interaction of the tapered surface 471 of the first housing portion 421 with the carrier surface 430a along the longitudinal (engagement) axis 196 causes relative movement between the carrier 430 and the frame 440 along the configuration axis 198. As the second housing portion 422 slides into the cavity 420a of the first housing portion 421, the tapered surface 471 interacts with a surface 472 of the carrier 430, moving the carrier 430 along the axis 198.

[0038] The actuators 170, 470 shown in Figures 1A-1G, 3A, 3B, 4A, and 4B are operable to move the carrier 130, 430 relative to the frame 140, 440 when the first housing portion 121, 421 engages the second housing portion 122, 422. In alternative embodiments, operation of the actuators to cause relative movement between the carrier and frame is independent of engagement of the housing portions.

[0039] 5A-5C show a connector 500 having an actuator 570 that can be operated independently of engagement of the first housing portion 521 and the second housing portion 522. FIG. 5A shows a partial perspective view of the first and second housing portions 521, 522 and the optical cable 110. Each optical cable 110 includes an optical waveguide array 111 that includes at least one optical waveguide attached to a ferrule 112. The first and second housing portions 521, 522 can be engaged prior to operation of the actuator 570. The housing 520 includes a carrier 530 and a frame 540. The carrier 530 includes a retainer mount 543 configured to receive and retain a cable retainer 113.

[0040] In the embodiment shown in FIGS. 5A-5C, the actuator 570 includes a cam 571 disposed within the housing 520 and configured to rotate about a pivot 572. Although the cam 571 is shown in FIG. 5A as being part of the first housing portion 521, the cam may alternatively be disposed on the second housing portion. Rotation of the cam 571 engages the cam 571 with a surface 530a of the carrier 530, moving the carrier 530 relative to the frame 540 along an axis 198 (the configuration axis). Movement of the carrier 530 relative to the frame 540 bends the optical waveguide array 111 and rotates the ferrule 112. The bend 111a of the optical waveguide array 111 provides a predetermined amount of mating spring force at a predetermined angle of the ferrule 112 when the ferrule 112 is mated with a mating ferrule.

[0041] The actuators 170, 470, 570 discussed herein may be configured to operate reversibly. Operation of the actuators 170, 470 of the connectors 100, 400 occurs when the first housing portion 121, 421 engages with the second housing portion 122, 422. Operating the actuators 170, 470 of the connectors 100, 300, 400 causes the carriers 130, 430 to move relative to the frames 149, 440 from an initial carrier / frame position (see FIG. 1B) to a second carrier / frame position (see FIG. 1A), thereby bending or bending the optical waveguide arrays 111, 411. Reversing the operation of the actuators 170, 470 of the connectors 100, 300, 400 involves disengagement of the first housing portion 121, 421 from the second housing portion 122, 422. Reversing the action of the actuator 170, 470 returns the carrier 130, 430 and frame 140, 440 from the second carrier / frame position to the initial carrier / frame position, where the optical waveguides are in a less bent or substantially straight configuration. The optical waveguide array 111, 411 can be removed from the carrier and frame without substantially damaging the waveguide array 111, 411, the carrier 130, 430, and / or the frame 140, 440.

[0042] Operation of actuator 570 of connector 500 occurs when cam 571 is rotated from an initial cam position (shown in FIG. 5B) to a second cam position (shown in FIG. 5C). Rotation of cam 571 moves carrier 530 from an initial carrier / frame position where optical waveguide array 111 is in a less bent or substantially straight configuration relative to frame 540 to a second carrier / frame position where optical waveguide array 511 is bent or more bent. Reversing operation of actuator 570 involves rotating cam 571 from the second cam position back to the initial cam position, thereby allowing carrier 530 to move from the second carrier / frame position back to the initial carrier / frame position.

[0043] The actuator that moves the carrier relative to the frame can have an actuator portion disposed in the first housing portion, the second housing portion, or both the first and second housing portions. As described above, the operation of the actuator can be dependent on the engagement of the first housing portion with the second housing portion, or can be independent of the engagement of the first housing portion with the second housing portion. For example, the actuator can be operated manually via an external knob or screw head. The operation of the actuator can be reversible or irreversible. Prior to operating the actuator to move the carrier relative to the frame, the carrier and frame are adapted to allow the carrier and frame to be installed in and subsequently removed from the second housing portion in a substantially straight or slightly bent configuration without damaging the second housing portion and / or the optical cable.

[0044] According to some embodiments, the optical connector 100, 300, 400, 500 includes a housing 120, 420, 520 with one or more waveguide support walls 131, 141, 331, 341, 431, 441, 531, 541 configured to support the optical cable 110, 410, 510. The waveguide support walls 131, 141, 431, 441, 531, 541 may be disposed on the carrier 130, 430, 530 and / or the frame 140, 440, 540 of the connector housing 120, 420, 520. Each waveguide support wall 131, 141, 431, 441, 531, 541 includes a surface 131c, 141c, 331c, 341c, 431c, 441c, 531c, 541c that is spaced apart from the mating surface 181, 481, 581 of the optical connector 100, 300, 400, 500. The one or more waveguide support walls 131, 141, 331, 341, 431, 441, 531, 541 are configured to allow the optical cable 110, 410, 510 to be inserted into the housing 120, 420, 520 along a direction substantially perpendicular to the mating axis 199 of the optical connector 100, 300, 400, 500.

[0045] As shown in Figures 1A, 1B, 3A, 3B, 4A, 4B, 5A, 5B, each waveguide support wall 131, 141, 431, 441, 531, 541 includes at least one inclined surface 131a, 141a, 431a, 441a, 531a, 541a configured to support the optical waveguide array 111, 411, 511 of the optical cable 110, 410, 510 at a predetermined angle θ relative to the mating axis 199 of the optical connector 100, 300, 400, 500. For example, the predetermined angle θ can be about 15 to about 25 degrees. In some embodiments, the predetermined angle is about 18 degrees. The waveguide support walls 131, 141, 431, 441, 531, 541 are adapted to allow one or more optical cables 110, 410, 510 to be installed within and subsequently removed from the carrier 130, 430, 530 and frame 140, 440, 540 without damaging the carrier 130, 430, 530, frame 140, 440, 540, and / or optical cables 110, 410, 510.

[0046] 6 is a flow diagram of a method for introducing an optical connector, according to some embodiments. One or more optical cables are inserted (610) into a housing comprising a carrier and a frame. Each optical cable comprises at least one optical waveguide and at least one optical ferrule attached to the waveguide. An actuator is operated (620) to move the carrier relative to the frame (630). In response to the relative movement between the carrier and the frame, the optical waveguides bend or flex and the ferrules rotate (640). The bending of the optical waveguide provides a predetermined spring force at a predetermined angle of the ferrule when the ferrule mates with a mating ferrule.

[0047] In some embodiments, the housing includes a first housing portion and a second housing portion comprising a carrier and a frame. Activating the actuator includes mechanically engaging the first housing portion with the second housing portion. According to some implementations, mechanically engaging the first housing portion with the second housing portion occurs independently of operating the actuator. For example, operating the actuator may occur after the first housing portion is fully engaged with the second housing portion. Activating the actuator may involve operating a cam or other structure that engages a surface of the carrier, which may be performed manually, for example, by turning an external knob or screw head. The carrier is moved relative to the frame in response to the engagement of the cam with a surface of the carrier.

[0048] In some embodiments, mechanically engaging the first housing portion and the second housing portion includes moving one or both of the first housing portion and the second housing portion along a transverse axis substantially perpendicular to a mating axis of the optical connector. In some embodiments, mechanically engaging the first housing portion and the second housing portion includes rotating one or both of the first housing portion and the second housing portion about a vertical axis substantially perpendicular to a mating axis of the optical connector. In other embodiments, mechanically engaging the first housing portion and the second housing portion includes rotating one or both of the first housing portion and the second housing portion about a longitudinal axis substantially parallel to a mating axis of the optical connector. In yet other embodiments, mechanically engaging the first housing portion and the second housing portion includes moving one or both of the first housing portion and the second housing portion along a longitudinal axis substantially parallel to a mating axis of the optical connector.

[0049] According to some variations of the method, multiple optical cables can be inserted into the housing simultaneously. In these variations, the multiple optical cables can include a common cable retainer. Alternatively, each optical cable can have a separate cable retainer and / or can be inserted into the housing separately. Inserting the optical cables can involve inserting a cable retainer into a retainer mount of the frame. In some embodiments, each optical cable is attached to a corresponding cable retainer. According to some variations of the method, the optical cables can be inserted into and attached to a carrier. The carrier is then inserted into the second housing portion.

[0050] The connector structure herein is configured such that one or more optical cables are inserted into the carrier and frame while the optical cables are substantially straight or slightly bent. The optical cables are inserted into the carrier and frame along a first insertion axis. For example, the first insertion axis may be substantially orthogonal or substantially parallel to the mating axis of the optical connector. According to some embodiments, the first insertion axis is a longitudinal axis that is substantially parallel to the mating axis of the optical connector. In some implementations, inserting the optical cables may involve inserting the optical cables along multiple orthogonal axes. After insertion of the optical cables into the carrier and frame, an actuator is operated to move the carrier relative to the frame along a configuration axis. According to some embodiments, the configuration axis is substantially orthogonal to at least one of the insertion axes.

[0051] Embodiments disclosed herein include the following.

[0052] Embodiment 1. one or more optical cables, each optical cable comprising at least one array of optical waveguides and at least one optical ferrule attached to the array of optical waveguides; and a housing; a first housing portion; and a second housing portion engaged with the first housing portion, the second housing portion comprising at least one carrier and a frame, the carrier and frame of the second housing portion configured to support one or more optical cables, the first housing portion and the second housing portion configured such that mechanical engagement between the first housing portion and the second housing portion moves the carrier relative to the frame, the movement of the carrier relative to the frame causing bending of each optical waveguide and rotation of each ferrule, the bending providing a predetermined spring force of the optical waveguide at a predetermined angle of the ferrule; a housing including: An optical connector comprising:

[0053] Embodiment 2. 2. An optical connector as described in embodiment 1, wherein the one or more optical cables are attached to the carrier by an adhesive.

[0054] Embodiment 3. 2. An optical connector as described in embodiment 1, wherein the optical cable is attached to the carrier by a friction grip.

[0055] Embodiment 4. 4. The optical connector according to any one of embodiments 1 to 3, wherein there is one carrier per frame.

[0056] Embodiment 5. 4. The optical connector according to any one of embodiments 1 to 3, wherein there are multiple carriers per frame.

[0057] Embodiment 6. 6. The optical connector according to any one of embodiments 1 to 5, wherein there are multiple frames per connector.

[0058] Embodiment 7. at least one cable retainer is attached to the array of waveguides of the one or more optical cables and spaced from the ferrules of the optical cables, the carrier including at least one retainer mount configured to receive the at least one cable retainer; 7. The optical connector according to any one of the first to sixth embodiments.

[0059] Embodiment 8. An optical connector as described in embodiment 7, wherein the at least one cable retainer is a single cable retainer attached to each waveguide of the multiple optical cables.

[0060] EMBODIMENT 9. An optical connector as described in embodiment 7, wherein the at least one cable retainer includes a plurality of cable retainers, and the one or more optical cables include a plurality of optical cables, each of the plurality of cable retainers being respectively attached to at least one waveguide of one of the plurality of optical cables.

[0061] Embodiment 10. 8. An optical connector as described in embodiment 7, wherein the optical cable is attached to the cable holder by adhesive.

[0062] Embodiment 11. 8. The optical connector of embodiment 7, wherein the optical cable is attached to the cable holder by a friction grip.

[0063] Embodiment 12. the one or more optical cables include a plurality of optical cables, each optical cable including a cable retainer attached to the array of waveguides of the optical cable and spaced from a ferrule of the optical cable, the carrier including a plurality of retainer mounts, each retainer mount configured to receive a corresponding cable retainer of the plurality of optical cables; 12. The optical connector according to any one of the first to eleventh embodiments.

[0064] Embodiment 13. 13. The optical connector according to any one of embodiments 1 to 12, wherein at least one optical waveguide array includes at least one optical fiber.

[0065] Embodiment 14. 13. The optical connector according to any one of embodiments 1 to 12, wherein at least one optical waveguide array includes a plurality of optical fibers.

[0066] EMBODIMENT 15. 13. The optical connector according to any one of embodiments 1 to 12, wherein the at least one optical waveguide array includes at least one planar waveguide disposed on a substrate.

[0067] Embodiment 16. 13. The optical connector according to any one of embodiments 1 to 12, wherein at least one optical waveguide array includes a plurality of planar waveguides arranged on a substrate.

[0068] EMBODIMENT 17. An optical connector according to any one of embodiments 1 to 16, wherein the frame includes one or more ferrule supports disposed at a mating end of the optical connector, the ferrule supports being configured to support a ferrule of an optical cable.

[0069] Embodiment 18. An optical connector according to any one of embodiments 1 to 17, wherein the one or more optical cables include at least four optical cables, the optical cables extending along a longitudinal axis of the connector and stacked within the connector housing along a vertical axis different from the longitudinal axis.

[0070] EMBODIMENT 19. An optical connector described in any one of embodiments 1 to 18, wherein the frame includes one or more frame waveguide support walls disposed between the mating end of the optical connector and the carrier, and each frame waveguide support wall is configured to support a corresponding optical waveguide.

[0071] EMBODIMENT 20. An optical connector as described in embodiment 19, wherein each frame waveguide support wall includes an inclined portion that supports the optical waveguide so that the optical waveguide forms a predetermined angle with respect to the mating axis of the optical connector.

[0072] EMBODIMENT 21. 21. The optical connector according to embodiment 20, wherein the predetermined angle is about 15 to about 25 degrees.

[0073] EMBODIMENT 22. 21. An optical connector as described in embodiment 20, wherein the predetermined angle is approximately 18 degrees.

[0074] EMBODIMENT 23. An optical connector as described in any one of embodiments 1 to 22, wherein the carrier includes one or more carrier waveguide support walls disposed between a mating end of the optical connector and a retainer mount of the carrier, each carrier waveguide support wall being configured to support a corresponding optical waveguide.

[0075] EMBODIMENT 24. An optical connector as described in embodiment 23, wherein each carrier waveguide support wall includes an inclined portion that supports an optical waveguide such that the optical waveguide is at a predetermined angle relative to the mating axis of the optical connector.

[0076] EMBODIMENT 25. 25. The optical connector according to embodiment 24, wherein the predetermined angle is about 15 to about 25 degrees.

[0077] 26. 25. An optical connector as described in embodiment 24, wherein the predetermined angle is approximately 18 degrees.

[0078] EMBODIMENT 27. An optical connector described in any one of embodiments 1 to 26, wherein prior to engagement of the first housing portion with the second housing portion, the carrier and frame are adapted to enable the optical cable to be installed within and subsequently removed from the carrier and frame without damaging the carrier, the frame, or the optical cable.

[0079] 28. the housing is configured to allow insertion of the optical cable into the carrier and frame while the waveguide of the optical cable is substantially straight or slightly bent prior to engagement of the first and second housing portions, and mechanical engagement of the first and second housing portions causes the waveguide to bend or become more bent; The optical connector according to any one of the first to seventh embodiments.

[0080] 29. An optical connector described in any one of embodiments 1 to 28, wherein the second housing portion is configured to enable insertion of an optical cable into the carrier and the frame along at least a first insertion axis, and the first housing portion and the second housing portion are configured to move the carrier relative to the frame along the configuration axis by mechanical engagement between the first housing portion and the second housing portion.

[0081] EMBODIMENT 30. 30. An optical connector as described in embodiment 29, wherein the first insertion axis is a horizontal axis substantially perpendicular to the mating axis of the optical connector.

[0082] EMBODIMENT 31. An optical connector as described in embodiment 29, wherein the configuration axis is a vertical axis that is substantially perpendicular to the mating axis of the optical connector.

[0083] EMBODIMENT 32. An optical connector as described in embodiment 29, wherein the second housing portion is configured to enable insertion of the optical cable into the carrier and frame along a first insertion axis and along a second insertion axis substantially perpendicular to the first insertion axis.

[0084] EMBODIMENT 33. An optical connector as described in embodiment 32, wherein the first insertion axis is a horizontal axis substantially perpendicular to the mating axis of the optical connector, and the second insertion axis is a longitudinal axis substantially parallel to the mating axis of the optical connector.

[0085] EMBODIMENT 34. 30. An optical connector as described in embodiment 29, wherein the configuration axis is substantially perpendicular to the first insertion axis.

[0086] EMBODIMENT 35. An optical connector as described in embodiment 29, wherein the configuration axis is a vertical axis substantially perpendicular to the mating axis.

[0087] EMBODIMENT 36. An optical connector described in any one of embodiments 1 to 35, wherein the frame and carrier are configured to enable insertion of an optical cable into the frame and carrier along a first insertion axis and a second insertion axis perpendicular to the first insertion axis prior to mechanical engagement between the first housing part and the second housing part, and the mechanical engagement between the first housing part and the second housing part moves the carrier relative to the frame along a configuration axis different from the first insertion axis and the second insertion axis.

[0088] 37. the first insertion axis is a horizontal axis substantially perpendicular to the mating axis of the optical connector; The second insertion axis is a longitudinal axis substantially parallel to the mating axis of the optical connector, and the configuration axis is a third axis substantially perpendicular to the mating axis. An optical connector as described in embodiment 36.

[0089] 38. An optical connector described in any one of embodiments 1 to 37, wherein the first housing portion and the second housing portion are configured such that mechanical engagement between the first housing portion and the second housing portion includes relative movement between the first housing portion and the second housing portion at least along a first engagement axis.

[0090] 39. An optical connector as described in embodiment 38, wherein the engagement axis is a longitudinal axis substantially parallel to the mating axis of the optical connector.

[0091] EMBODIMENT 40. An optical connector as described in embodiment 38, wherein the engagement axis is a horizontal axis substantially perpendicular to the mating axis of the optical connector.

[0092] EMBODIMENT 41. An optical connector described in any one of embodiments 1 to 40, wherein the first housing portion and the second housing portion are configured such that mechanical engagement between the first housing portion and the second housing portion includes rotational movement of the first housing portion and the second housing portion around a rotational engagement axis.

[0093] EMBODIMENT 42. An optical connector as described in embodiment 41, wherein the rotation axis is a vertical axis substantially perpendicular to the mating axis of the optical connector.

[0094] EMBODIMENT 43. An optical connector as described in embodiment 41, wherein the rotation axis is a longitudinal axis substantially parallel to the mating axis of the optical connector.

[0095] EMBODIMENT 44. one or more optical cables, each optical cable comprising at least one array of optical waveguides and at least one optical ferrule attached to the array of optical waveguides; a housing comprising at least one carrier and a frame configured to support one or more optical cables; and an actuator configured such that operation of the actuator causes relative movement between the carrier and the frame, the relative movement between the carrier and the frame causing bending of the optical waveguide and rotation of the ferrule, the bending providing a predetermined spring force of the waveguide at a predetermined angle of the ferrule relative to a mating axis of the optical connector; An optical connector comprising:

[0096] EMBODIMENT 45. An optical connector as described in embodiment 44, wherein the housing includes a first housing portion and a second housing portion engaged with the first housing portion, the second housing portion comprising a carrier and a frame.

[0097] EMBODIMENT 46. An optical connector as described in embodiment 45, wherein the actuator is configured such that operation of the actuator occurs when the first housing portion and the second housing portion are mechanically engaged.

[0098] EMBODIMENT 47. 46. ​​The optical connector of claim 45, wherein the actuator is configured to operate independently of mechanical engagement between the first and second housing portions.

[0099] 48. An optical connector as described in embodiment 45, wherein the actuator is configured to be manually operated after engagement of the first housing portion and the second housing portion.

[0100] 49. An optical connector as described in embodiment 45, wherein the actuator is configured to operate reversibly such that reversing operation of the actuator straightens the bend in the optical waveguide.

[0101] EMBODIMENT 50. An optical connector as described in embodiment 45, wherein the actuator is disposed in the first housing portion, the second housing portion, or both the first and second housing portions.

[0102] EMBODIMENT 51. An optical connector as described in embodiment 45, wherein at least a portion of the actuator is disposed on the carrier.

[0103] EMBODIMENT 52. An optical connector as described in embodiment 45, wherein at least a portion of the actuator is disposed on the frame.

[0104] EMBODIMENT 53. An optical connector described in any one of embodiments 44 to 52, wherein prior to operation of the actuator, the carrier and frame are adapted to enable the optical cable to be installed within and subsequently removed from the second housing portion without damaging the second housing portion and the optical cable.

[0105] EMBODIMENT 54. The second housing portion is configured to allow insertion of the optical cable into the carrier and the frame along at least a first insertion axis, and the actuator is configured such that operation of the actuator moves the carrier relative to the frame along the configuration axis. The optical connector according to any one of embodiments 44 to 53.

[0106] EMBODIMENT 55. An optical connector as described in embodiment 54, wherein the configuration axis is substantially perpendicular to the first insertion axis.

[0107] EMBODIMENT 56. An optical connector as described in embodiment 54, wherein the first insertion axis is a horizontal axis substantially perpendicular to the mating axis of the optical connector.

[0108] EMBODIMENT 57. An optical connector as described in embodiment 54, wherein the first insertion axis is a longitudinal axis substantially parallel to the mating axis of the optical connector.

[0109] EMBODIMENT 58. An optical connector as described in embodiment 54, wherein the configuration axis is a vertical axis substantially perpendicular to the mating axis of the optical connector.

[0110] EMBODIMENT 59. 55. An optical connector as described in embodiment 54, wherein the configuration axis is a longitudinal axis (196) substantially parallel to the mating axis of the optical connector.

[0111] 60. An optical connector as described in embodiment 54, wherein the second housing portion is configured to enable insertion of the optical cable into the carrier and frame along the first insertion axis and along the second insertion axis.

[0112] 61. An optical connector as described in embodiment 60, wherein the first insertion axis is a horizontal axis substantially perpendicular to the mating axis of the optical connector, and the second insertion axis is a longitudinal axis substantially parallel to the mating axis.

[0113] 62. The carrier and the frame are configured to allow insertion of the optical cable into the frame and the carrier along a first insertion axis and a second insertion axis orthogonal to the first insertion axis prior to mechanical engagement of the first and second housing portions, and the actuator is configured such that operation of the actuator moves the carrier relative to the frame along the configuration axis. The optical connector according to any one of embodiments 44 to 61.

[0114] 63. The first insertion axis is a horizontal axis substantially perpendicular to the mating axis of the optical connector, the second insertion axis is a longitudinal axis substantially parallel to the mating axis of the optical connector, and the first configuration axis is a vertical axis substantially perpendicular to the mating axis. An optical connector as described in embodiment 62.

[0115] 64. the housing includes a first housing portion engaged with a second housing portion including a carrier and a frame, and the actuator includes a rib disposed on the first housing portion, the rib configured to interact with a surface of the carrier to cause relative movement between the carrier and the frame during mechanical engagement of the first housing portion and the second housing portion; The optical connector according to any one of embodiments 44 to 63.

[0116] 65. 65. An optical connector as described in embodiment 64, wherein the rib includes an inclined surface.

[0117] 66. An optical connector as described in embodiment 65, wherein the surface of the carrier includes an inclined surface complementary to the inclined surface of the rib.

[0118] 67. An optical connector as described in any one of embodiments 44 to 66, wherein the housing includes a first housing portion engaged with a second housing portion including a carrier and a frame, and the actuator includes a surface of the carrier, the surface being configured to interact with a rib of the first housing portion to cause relative movement between the carrier and the frame during mechanical engagement of the first housing portion and the second housing portion.

[0119] 68. the actuator includes a tapered surface of the first housing portion and a surface of the carrier, and engagement of the tapered surface of the first housing portion with the surface of the carrier causes relative movement between the carrier and the frame; The optical connector according to any one of embodiments 44 to 66.

[0120] 69. An optical connector described in any one of embodiments 44 to 66, wherein the actuator includes a cam disposed within the housing and a surface of the carrier, and engagement between the cam and the surface of the carrier causes relative movement between the carrier and the frame.

[0121] EMBODIMENT 70. one or more optical cables, each optical cable comprising at least one array of optical waveguides and at least one optical ferrule attached to the optical waveguides; a housing including one or more waveguide support walls, each configured to allow insertion of an optical cable into the housing when a waveguide of the optical cable is in a substantially straight configuration, each waveguide support wall having an angled surface that supports the waveguide at an angle relative to a mating axis of the optical connector after the waveguide is bent within the housing; An optical connector comprising:

[0122] EMBODIMENT 71. 71. The optical connector according to embodiment 70, wherein the predetermined angle is about 15 degrees to about 25 degrees.

[0123] EMBODIMENT 72. An optical connector as described in embodiment 70, wherein the predetermined angle is approximately 18 degrees.

[0124] EMBODIMENT 73. An optical connector as described in any one of embodiments 70 to 72, wherein the waveguide support wall is adapted to allow one or more optical cables to be installed within the frame and subsequently removed therefrom without damaging the frame or the optical cables.

[0125] 74. An optical connector according to any one of embodiments 70 to 73, wherein the housing includes a carrier and a frame configured to move relative to each other, and movement of the carrier relative to the frame bends the waveguide.

[0126] 75. An optical connector as described in embodiment 74, wherein the waveguide support wall is disposed on one or both of the carrier and the frame.

[0127] 76. An optical connector as described in embodiment 74, wherein the waveguide support wall includes one or more waveguide support walls on a carrier.

[0128] EMBODIMENT 77. An optical connector as described in embodiment 74, wherein the waveguide support wall includes one or more waveguide support walls on the frame.

[0129] 78. each optical cable includes a cable retainer spaced from the ferrule and attached to the waveguide, the carrier including at least one retainer mount configured to receive the cable retainer; An optical connector as described in embodiment 74.

[0130] 79. the housing includes a carrier and a frame configured to move relative to one another, the retainer mount being disposed within the carrier such that movement of the carrier relative to the frame bends the waveguide; An optical connector as described in embodiment 78.

[0131] 80. The housing is a first housing portion; and a second housing portion engaged with the first housing portion, the second housing portion comprising a carrier and a frame configured to move relative to one another, engagement of the first housing portion with the second housing portion causing relative movement of the carrier and the frame, the relative movement of the carrier and the frame causing bending of the waveguide within the housing; 80. The optical connector according to any one of embodiments 70 to 79, comprising:

[0132] 81. 81. The optical connector of any one of embodiments 70 to 80, wherein each waveguide support wall includes a surface that is spaced apart from a mating surface of the optical connector.

[0133] 82. one or more optical cables, each optical cable comprising at least one array of optical waveguides and at least one optical ferrule attached to the optical waveguide array; and a housing comprising one or more waveguide support walls configured to support the optical cables, the one or more waveguide support walls configured to permit insertion of the optical cables into the housing along a direction substantially perpendicular to a mating axis of the optical connector; An optical connector comprising:

[0134] 83. An optical connector as described in embodiment 82, wherein each waveguide support wall includes an inclined surface configured to support an optical waveguide of the optical cable at a predetermined angle relative to the mating axis of the optical connector.

[0135] 84. An optical connector as described in embodiment 82 or 83, wherein the housing includes a carrier and a frame configured to move relative to each other, and one or both of the carrier and the frame include a waveguide support wall.

[0136] 85. An optical connector as described in embodiment 84, wherein the one or more waveguide support walls are configured to allow insertion of an optical cable into the carrier and frame in a substantially straight or slightly bent configuration, and relative movement between the carrier and frame causes the optical waveguide to bend or become more bent.

[0137] 86. at least one array of optical waveguides having a longitudinal axis; at least one optical ferrule attached to the array of optical waveguides; and a cable holder attached to the optical waveguides and spaced from the ferrules, such that when the optical waveguides are held by the cable holder such that a portion of the optical waveguide in the cable holder is horizontally straight with respect to gravity, the portion of the optical waveguide in the ferrule sags by less than a predetermined percentage x% of a distance d between the cable holder and the optical ferrule; An optical cable comprising:

[0138] 87. 87. The optical cable of embodiment 86, wherein x% is about 20%.

[0139] 88. 87. The optical cable of embodiment 86, wherein x% is about 10%.

[0140] 89. 87. The optical cable of embodiment 86, wherein x% is about 5%.

[0141] EMBODIMENT 90. 87. The optical cable of embodiment 86, wherein x% is about 1%.

[0142] EMBODIMENT 91. An optical cable as described in embodiment 86, wherein the distance is about 4 cm.

[0143] EMBODIMENT 92. An optical cable as described in embodiment 86, wherein the distance is about 1.8 cm.

[0144] EMBODIMENT 93. 87. The optical cable of embodiment 86, wherein at least one optical waveguide comprises an optical fiber.

[0145] EMBODIMENT 94. 87. The optical cable of embodiment 86, wherein at least one optical waveguide comprises a waveguide array of multiple optical fibers.

[0146] EMBODIMENT 95. 87. An optical cable as described in embodiment 86, wherein the at least one optical waveguide includes at least one planar waveguide disposed on a substrate.

[0147] EMBODIMENT 96. 87. An optical cable as described in embodiment 86, wherein the at least one optical waveguide includes a plurality of planar waveguides arranged on a substrate.

[0148] EMBODIMENT 97. A method for assembling an optical connector, comprising the steps of: inserting one or more optical cables into a housing comprising a carrier and a frame, each optical cable comprising at least one optical waveguide and at least one optical ferrule; activating an actuator; and moving the carrier relative to the frame in response to actuation of the actuator; and bending the optical waveguide and rotating the ferrule in response to movement of the carrier relative to the frame, the bending of the optical waveguide providing a predetermined spring force at a predetermined angle of the ferrule; A method comprising:

[0149] EMBODIMENT 98. the housing includes a first housing portion and a second housing portion having a frame and an actuator, and actuating the actuator includes mechanically engaging the first housing portion and the second housing portion; The method according to embodiment 97.

[0150] EMBODIMENT 99. The housing portion includes a first housing portion and a second housing portion having a frame and an actuator, and the method includes: mechanically engaging the first housing portion and the second housing portion; and operating the actuator after mechanically engaging the first housing portion and the second housing portion; 99. The method of embodiment 97 or 98, further comprising:

[0151] EMBODIMENT 100. The method of embodiment 99, wherein mechanically engaging the first housing portion and the second housing portion includes moving one or both of the first housing portion and the second housing portion along a lateral axis substantially perpendicular to the mating axis of the optical connector.

[0152] EMBODIMENT 101. The method of embodiment 99, wherein mechanically engaging the first housing portion and the second housing portion includes rotating one or both of the first housing portion and the second housing portion about a vertical axis substantially perpendicular to the mating axis of the optical connector.

[0153] EMBODIMENT 102. The method of embodiment 99, wherein mechanically engaging the first housing portion and the second housing portion includes rotating one or both of the first housing portion and the second housing portion about a longitudinal axis substantially parallel to the mating axis of the optical connector.

[0154] EMBODIMENT 103. The method of embodiment 99, wherein mechanically engaging the first housing portion and the second housing portion includes moving one or both of the first housing portion and the second housing portion along a longitudinal axis substantially parallel to the mating axis of the optical connector.

[0155] EMBODIMENT 104. the housing includes a first housing portion and a second housing portion comprising a carrier and a frame; A method according to any one of embodiments 97 to 103, wherein operating the actuator includes operating a cam that engages with a surface of the carrier, and moving the carrier relative to the frame includes moving the carrier relative to the frame in response to the cam engaging with the surface of the carrier.

[0156] EMBODIMENT 105. A method according to any one of embodiments 97 to 104, wherein inserting one or more optical cables includes simultaneously inserting multiple optical cables.

[0157] EMBODIMENT 106. A method according to any one of embodiments 97 to 105, wherein each optical cable includes a cable holder attached to the waveguide, and inserting the one or more optical cables includes inserting the cable holder into a holder mount of the frame.

[0158] EMBODIMENT 107. 107. The method of embodiment 106, wherein one cable holder is attached to multiple arrays of optical waveguides, and each array of optical waveguides is attached to a corresponding optical ferrule.

[0159] EMBODIMENT 108. Inserting one or more optical cables inserting the optical cable into a carrier and then inserting the carrier into a frame. The method according to any one of embodiments 97 to 107.

[0160] EMBODIMENT 109. The method of any one of embodiments 97 to 108, further comprising removing one or more optical cables from the housing without damaging the housing or the optical cables.

[0161] EMBODIMENT 110. A method as described in any one of embodiments 97 to 109, wherein inserting one or more optical cables includes inserting one or more optical cables into the carrier and frame while the optical waveguide is substantially straight or slightly bent.

[0162] EMBODIMENT 111. inserting the optical cable includes inserting the optical cable into the carrier and the frame along at least a first insertion axis, and moving the carrier relative to the frame in response to actuation of the actuator includes moving the carrier relative to the frame along a configuration axis orthogonal to the first insertion axis. An optical connector according to any one of embodiments 97 to 110.

[0163] EMBODIMENT 112. An optical connector as described in embodiment 111, wherein the first insertion axis is a horizontal axis substantially perpendicular to the mating of the optical connector.

[0164] EMBODIMENT 113. An optical connector as described in embodiment 111, wherein the first insertion axis is a longitudinal axis substantially parallel to the mating axis of the optical connector.

[0165] EMBODIMENT 114. An optical connector as described in embodiment 111, wherein inserting the optical cable includes inserting the optical cable into the carrier and frame along a first insertion axis and along a second insertion axis, the first insertion axis being a horizontal axis substantially perpendicular to the mating axis of the optical connector, and the second insertion axis being a longitudinal axis substantially parallel to the mating axis.

[0166] EMBODIMENT 115. An optical connector as described in embodiment 111, wherein the configuration axis is a vertical axis substantially perpendicular to the mating axis of the optical connector.

[0167] Unless otherwise indicated, all numbers expressing feature sizes, quantities, and physical properties used in the specification and claims are to be understood as being modified in all instances by the term "about." Accordingly, unless specifically indicated to the contrary, the numerical parameters set forth in the above specification and appended claims are approximations that may vary depending upon the desired properties one of ordinary skill in the art would obtain using the teachings disclosed herein. The use of numerical ranges by endpoints includes all numbers within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5) and any range within that range.

[0168] Various modifications and changes to the above-mentioned embodiments will be apparent to those skilled in the art, and it should be understood that the present disclosure is not limited to the exemplary embodiments described herein. The reader should assume that the features of one disclosed embodiment can also be applied to all other disclosed embodiments, unless otherwise indicated. It should also be understood that all U.S. patents, patent applications, patent application publications, and other patent and non-patent documents referenced in this specification are incorporated herein by reference to the extent that they do not contradict the above disclosure.

Claims

1. An optical connector configured to mate with another optical connector, one or more optical cables, each comprising an optical waveguide and an optical ferrule attached to the optical waveguide; a housing comprising a first housing portion and a second housing portion engaging the first housing portion; Equipped with the second housing portion includes one or more waveguide support walls, each configured to allow insertion of the optical cable into the second housing portion when the optical waveguide of the optical cable is in a straight configuration, each waveguide support wall having an angled surface that supports the optical waveguide at an angle relative to a mating axis of the optical connector after the optical waveguide is bent within the second housing portion; An optical connector, wherein the second housing portion includes a carrier and a frame configured to move relative to each other, and movement of the carrier relative to the frame is caused by engagement between the first housing portion and the second housing portion, thereby bending the optical waveguide.

2. 2. The optical connector according to claim 1, wherein the predetermined angle is between 15 degrees and 25 degrees.

3. 2. The optical connector of claim 1, wherein the waveguide support wall is adapted to allow the one or more optical cables to be installed within the frame and subsequently removed therefrom without damaging the frame or the optical cables.

4. A method for assembling the optical connector according to any one of claims 1 to 3, comprising the steps of: inserting the one or more optical cables into the second housing portion; moving the carrier relative to the frame by engaging the first housing portion and the second housing portion; bending the optical waveguide and rotating the optical ferrule in response to movement of the carrier relative to the frame, the bending of the optical waveguide providing a predetermined spring force at a predetermined angle of the optical ferrule; A method comprising:

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