FIBER OPTIC CONNECTORS THAT HAVE A CODING STRUCTURE AND METHODS FOR MANUFACTURING THEM

Abstract

Optical fiber connectors, cable assemblies, and methods for manufacturing them are described. In one embodiment, the optical connector comprises a housing and a multifiber ferrule. The housing comprises a longitudinal channel between a rear end and a front end, and a rear portion of the housing comprises a coding or keying portion and at least one locking feature integrally formed in the rear portion of the housing.

Description

FIBER OPTIC CONNECTORS THAT HAVE A STRUCTURE OF CODING AND METHODS FOR MANUFACTURING THEM QAOQnn / zznz / E / YiAi CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Application No. 62 / 428,212, filed November 30, 2016, U.S. Application No. 62 / 428,219, filed November 30, 2016, U.S. Application No. 62 / 428,224, filed November 30, 2016, U.S. Application No. 62 / 428,230, filed November 30, 2016, U.S. Application No. 62 / 428,234, filed November 30, 2016, U.S. Application No. 62 / 428,244, filed on November 30, 2016, United States Application No. 62 / 428,252, filed on November 30, 2016, United States Application No. 62 / 451,221, filed on January 27, 2017, United States Application No. 62 / 451,234, filed on January 27, 2017, United States Application No. 62 / 526,011, filed on June 28, 2017, United States Application No. 62 / 526,018, filed on June 28, 2017, and United States Application No. 62 / 526,195, filed on June 28, 2017, the contents of which are based upon and incorporated herein by reference in their entirety. PREVIOUS TECHNIQUE

[0002] The disclosure pertains to fiber optic connectors and methods for manufacturing fiber optic connectors. More specifically, the disclosure pertains to fiber optic connectors with improved or simplified designs and manufacturing methods.

[0003] Optical fiber is increasingly used for a variety of applications, including, but not limited to, broadband voice, video, and data transmission. As bandwidth demands increase, optical fiber is migrating to subscribers in outdoor communication networks, such as fiber optics, and to local applications such as FTTx and similar services. To address this need for optical connections in communication networks for outdoor environments, hardened optical fiber connectors were developed. One of the most commercially successful hardened optical fiber connectors is the OptiTap® connector sold by Corning Optical Communications LLC of Hickory, North Carolina, as described in U.S. Patent Nos. 7,090,406 and 7,113,679 (the '406 and '679 patents). The OptiTap® connector is a hardened male connector for terminating an optical fiber cable, and the assembly is configured for an optical connection, such as with a complementary receptacle.As used herein, the term hardened describes a connector or receptacle port intended to make an environmentally sealed optical connection suitable for outdoor use, and the term nonhardened describes a connector or receptacle port that is not intended to make a sealed optical connection such as the well-known SC connector.

[0004] Figures 1A-1C are prior art representations showing various stages of mating a pre-wired cable 1 having a connector 5, such as an OptiTap® connector, with a receptacle 3. The receptacle 3 connects the connector 5 to a standard SC connector (i.e., hardened connector) at a second end (not visible in these views) using an adapter sleeve to align ferrules when connecting the connector 5 to a non-hardened connector. Protection of the non-hardened connector side of the receptacle is typically achieved by mounting the receptacle 3 through a wall of an enclosure or similar structure, so that the non-hardened end of the receptacle is disposed within the enclosure for environmental protection of the non-hardened connector. As shown in Figures 1A-1C, the other end of the receptacle 3 is accessible to receive the plug connector 5 on the enclosure wall.Other applications may mount receptacle 3 inside a box on a stand or similar.

[0005] Receptacle 3 allows an optical connection between the hardened connector, such as the OptiTap® male connector, and a non-hardened connector, such as the SC connector in the QAOQnn / zznz / E / γΐΛΐ optical network nodes that typically transition from an outdoor space to a protected, enclosed space. Receptacle 3 is described in more detail in U.S. Patent No. 6,579,014. Receptacle 3 includes a receptacle housing and an adapter sleeve disposed therein. Receptacle 3 receives a non-hardened connector at a second end, as represented by the arrow pointing to the left. Receptacle 3 generally requires mounting through a wall of an enclosure, or within an enclosure, such as a side-mounted enclosure at subscriber premises, arranged in an underground vault, or on a pole to protect the non-hardened connector for outside plant deployments.

[0006] Network operators face many challenges in building, deploying, and connecting subscribers to off-site communication networks, such as Fiber to the Home (FTTH) or Fiber to the Location (FTTx) networks. In addition to right-of-way access for communication networks, network operators may have limited space available on existing poles or in existing vaults for mounting equipment. Initially, conventional hardened fiber optic connectors were typically mounted on robust and relatively rigid fiber optic cables, and loose storage for these fiber optic cables can also consume limited space or become unsightly. QAOQnn / zznz / E / YiAi aerial deployments. Furthermore, as outside plant deployments evolved, many network operators wanted to route the fiber optic cable assembly with the connector through an existing wall of a subscriber's premises and into the building, or route the fiber optic cable assembly with the connector through a buried conduit. Therefore, network operators are sensitive to the size of the fiber optic connector for these types of deployment applications.

[0007] Consequently, there is an unmet need for fiber optic connectors that allow for quick and easy implementation and connectivity in a simple and efficient manner while remaining cost-effective. BRIEF DESCRIPTION OF THE INVENTION

[0008] The disclosure relates to optical fiber connectors and methods for manufacturing optical fiber connectors as described and recited in the claim. The described concepts allow for a compact form factor for an optical fiber connector suitable for numerous applications and variations as desired.

[0009] One aspect of the disclosure relates to an optical fiber connector comprising a housing and a ferrule comprising at least one fiber hole. The housing comprises a rear end and a front end. QAOQnn / zznz / E / YiAi with a longitudinal duct extending from the rear end to the front end. The housing comprises a front portion and a rear portion, where the rear portion of the housing comprises a coding portion, and at least one locking feature integrally formed in the rear portion of the housing.

[0010] Another aspect of the disclosure relates to an optical fiber connector comprising a housing and a ferrule comprising at least one fiber hole. The housing comprises a rear end and a front end with a longitudinal conduit extending from the rear end to the front end. The housing comprises a front portion and a rear portion, wherein the rear portion of the housing comprises a female encoder and at least one locking feature integrally formed in the rear portion of the housing.

[0011] Yet another aspect of the disclosure is directed to a fiber optic connector comprising a housing and a ferrule comprising at least one fiber hole. The housing comprises a rear end and a front end with a longitudinal conduit extending from the rear end to the front end. The housing comprises a front portion and a rear portion, wherein the rear portion of the housing comprises a female encoder and at least one locking feature. QAOQnn / zznz / E / γΐΛΐ formed integrally in the rear portion of the housing, and at least one locking feature is arranged approximately 180 degrees from the female encoder.

[0012] Another aspect of the description is directed to an optical fiber connector comprising a housing and a ferrule comprising at least one fiber hole. The housing comprises a rear end and a front end with a longitudinal channel extending from the rear end to the front end. The housing comprises a front portion, a rear portion, and a transition region disposed between the front and rear portions of the housing, wherein the rear portion of the housing comprises an encoding portion extending within a portion of the transition region, and at least one locking feature integrally formed in the rear portion of the housing, and at least one locking feature is disposed about 180 degrees from the encoding portion.

[0013] An additional aspect of the description pertains to a fiber optic connector comprising a housing and a ferrule comprising at least one fiber hole. The housing comprises a rear end and a front end with a longitudinal channel extending from the rear end to the front end. The housing comprises a front portion, a rear portion QAOQnn / zznz / E / γΐΛΐ and a transition region disposed between the front portion and the rear portion of the housing, wherein the rear portion of the housing comprises a female encoder extending into a portion of the transition region, and at least one locking feature integrally formed in the rear portion of the housing, the transition region comprising a threaded portion and at least one locking feature being disposed about 180 degrees from the female encoder.

[0014] Another aspect of the disclosure relates to a fiber optic connector comprising a housing, a ferrule comprising at least one fiber hole, a cable adapter, a sleeve attached to the cable adapter, and a sealing element. The housing comprises a rear end and a front end with a longitudinal channel extending from the rear end to the front end, and the rear end comprises a rear opening. The cable adapter is sized to fit into the rear opening of the housing, and the sealing element is arranged around a portion of the sleeve and a portion of a rear portion of the housing.

[0015] Additional features and advantages will be set forth in the detailed description that follows, and will in part be readily apparent to those skilled in the art from that description or will be recognized by practicing the same as described herein, including the detailed description that follows, the claims, as well as the accompanying drawings.

[0016] It should be understood that both the foregoing general description and the following detailed description present embodiments intended to provide an overview or framework for understanding the nature and character of the claims. The accompanying drawings are included to provide a better understanding of the disclosure and are incorporated herein and form a part of this specification. The drawings illustrate various embodiments and, together with the description, serve to explain the principles and operation. BRIEF DESCRIPTION OF THE FIGURES

[0017] Figs. 1A-1C are prior art representations showing various stages of mating a prior art pre-wired cable having a conventional hardened plug connector with a receptacle;

[0018] Figure 2 is a perspective view of a fiber optic cable assembly having a fiber optic connector with a housing in accordance with one aspect of the disclosure;

[0019] Figure 2A is a perspective view of another fiber optic cable assembly having a connector of QAOQnn / zznz / E / YiAi optical fiber with a portion of encoding according to an aspect of the disclosure;

[0020] Figure 3 is an exploded view of the fiber optic cable assembly of Fig. 2;

[0021] Figure 4 is a close-up perspective view of an optical fiber connector having a housing that is similar to the housing in FIG. 2 and representing geometric features of the housing in accordance with one aspect of the disclosure;

[0022] Figs. 4A-4D are respective cross-sectional views of the housing in FIG. 4 taken along the respective planes defined by lines 4A-4A, line 4B-4B, line 4C-4C and line 4D-4D;

[0023] Figure 4E is a side view of an explanatory housing that is similar to the housing shown on the fiber optic connector. 4 and also include threads that are discontinuous on the front portion;

[0024] Figure 5 is an exploded view of a ferrule subassembly of the fiber optic connector of FIG. 3;

[0025] Figs. 6 and 7 are longitudinal section views of the ferrule subassembly cable assembly of FIG. 3;

[0026] Figure 8 is a perspective view of the splint carrier of the splint subassembly of FIG. 3; QAOQnn / zznz / E / YiAi

[0027] Figure 9 is a close-up perspective view of the front end of the splint carrier of FIG. 8;

[0028] Figure 10 is a perspective view of an alternative splint support that can be used with the splint subassemblies described herein;

[0029] Figs. 11 and 12, respectively, are a partially exploded view and an assembled view of the alternative splint support depicted in FIG. 10;

[0030] Figs. 13 and 14, respectively, are a partial sectional view and a cross-sectional view of the alternative ferrule carrier of Figs. 10-12 depicted mounted in a fiber optic connector housing;

[0031] Figs. 15 and 16 are longitudinal section views of the fiber optic cable assembly of Fig. 2 showing construction details;

[0032] Figure 17 is an exploded view of another fiber optic cable assembly that is similar to the fiber optic cable assembly in FIG. 2 with a fiber optic connector having a different ferrule subassembly;

[0033] Figure 18 is a partially exploded view of the fiber optic cable assembly of FIG. 17 with the fiber optic cable connected to the ferrule subassembly;

[0034] Figure 19 is a perspective view of another cable assembly having a different fiber optic connector with a housing that is similar to the housing shown with the fiber optic connector in FIG. 2 according to another aspect of the disclosure;

[0035] Figure 20 is a close-up perspective view of the fiber optic connector in Fig. 19 depicting geometric features of the housing;

[0036] Figure 21 is an exploded view of another fiber optic cable assembly similar to that in Fig. 19 with a fiber optic connector having a housing having threads that are discontinuous according to another aspect of the disclosure;

[0037] Figure 22 is a perspective mounted view of the fiber optic cable assembly of Fig. 21;

[0038] Figure 23 is a perspective view of the cable assembly of Fig. 22 with a dust cap installed on the fiber optic connector;

[0039] Figure 24 is a longitudinal cross-sectional view of the cable assembly of Fig. 22 in the vertical direction;

[0040] Figure 25 is a detailed exploded view of the front end and fiber optic connector of FIG. QAOQnn / zznz / E / γΐΛΐ 22;

[0041] Figure 26 is a cross-sectional view taken at an opening in the housing and showing a transverse ferrule retaining member securing the fiber optic connector ferrule of FIG. 22;

[0042] Figs. 27 and 28, respectively, are a detailed view of an alternative transverse splint retention member and a cross-sectional view showing the alternative transverse splint retention member for securing the splint;

[0043] Figure 29 is a longitudinal cross-sectional view of a front portion of the fiber optic connector of FIG. 22 in the horizontal direction;

[0044] Figure 30 is a front section view of a housing having a tuning pocket that allows rotational tuning of the ferrule during manufacturing to improve optical performance;

[0045] Figs. 31 and 32 represent explanatory splints that have at least one selectively adjustable surface;

[0046] Figs. 33-36 are various views representing the fiber optic connector housing of FIG. 23;

[0047] Figure 37 is a perspective view of another fiber optic cable assembly with yet another alternative fiber optic connector having a nozzle;

[0048] Figure 38 is a perspective view of the fiber optic cable assembly of Fig. 37 showing a cross-sectional view of a dust plug having a pull eye and which can be secured to the thread disposed in the housing;

[0049] Figure 39 is an exploded view of the cable assembly of Fig. 37;

[0050] Figure 40 is a front section view of the fiber optic connector of Fig. 37 showing the nozzle attached to the front end of the housing;

[0051] Figure 41 is a front view of the housing of Fig. 37 showing a clamping surface, such as a weld interface on the housing, so that the nozzle can be attached to the housing so as to cover an opening for the retaining member of the cross ferrule;

[0052] Figs. 42 and 43 are perspective and side views of a fiber optic connector similar to FIG. 37 having an alternative housing with a coding feature for fiber optic connectors;

[0053] Figs. 44 and 45 are perspective views of alternative housings representing other locking feature designs for use with the described fiber optic connectors;

[0054] Figure 46 is a perspective view of QAOQnn / zznz / E / γΐΛΐ another fiber optic cable assembly that has a cable adapter that fits into a rear opening of a housing that can be changed for different types of fiber optic cables;

[0055] Figs. 47 and 48, respectively, are a perspective view and a cross-sectional view of the cable adapter of Fig. 4 6;

[0056] Figs. 47A and 48A are respectively a perspective view and a cross-sectional view of another cable adapter;

[0057] Figure 49 is a cross-sectional view of the rear portion of an explanatory fiber optic cable assembly showing the fiber optic cable inside the cable adapter taken in a vertical direction to represent how the cable can be connected to the fiber optic connectors described herein;

[0058] Figure 50 is a cross-sectional view of the rear portion of the cable assembly of Fig. 46 showing the fiber optic cable inside the cable adapter held in the horizontal direction;

[0059] Figures 51-54 are various views of another fiber optic cable assembly having an encoding portion configured as a female encoder; Figures 51A-53A are various views of a portion of another fiber optic cable assembly having a cable adapter with QAOQnn / zznz / E / γΐΛΐ flexes for cable bending stress relief;

[0060] Figure 54A is a front perspective view of another housing that can be used with the fiber optic connector concepts described herein;

[0061] Figure 55 represents a distribution cable having a fiber optic connector according to the concepts described arranged on a strap;

[0062] Figure 56 is a perspective view of an explanatory fiber optic connector further comprising a conversion housing bonded around the housing for changing the fiber optic connector from first connector indentations to second connector indentations;

[0063] Figure 57 is a cross-sectional view of the fiber optic connector of Fig. 56;

[0064] Figure 58 is a partially exploded view of an explanatory fiber optic connector showing the fiber optic connector with first connector indentations along with a conversion housing to change the fiber optic connector to second connector indentations which are hardened connector indentations;

[0065] Figure 59 is an assembled view of the fiber optic connector of Fig. 58 showing the second QAOQnn / zznz / E / YiAi connector indentations as a hardened connector indentation with the dust cap removed for clarity;

[0066] Figure 60 is an assembled view of the fiber optic connector of Fig. 58 showing the indentations of the second connector with the dust cap installed;

[0067] Figure 61 is a cross-sectional view of the fiber optic connector of Fig. 60

[0068] Figure 62 is a perspective view of an explanatory fiber optic connector that may have a conversion housing attached around the housing to change the fiber optic connector from first connector indentations to second connector indentations;

[0069] Figure 63 is an assembled view of the fiber optic connector of Fig. 62 after conversion to a second connector indentation configured as a hardened connector indentation with the dust cap removed for clarity;

[0070] Figure 64 is a partially exploded view of the fiber optic connector of Fig. 63;

[0071] Figure 65 is a cross-sectional view of the conversion housing and coupling nut of the fiber optic connector of FIG. 63;

[0072] Figs. 66 and 67 are cross-sectional views of the fiber optic connector of Fig. 63;

[0073] Figs. 68 and 69 are perspective views QAOQnn / zznz / E / γΐΛΐ of the retention member of the optical fiber connector of FIG. 63;

[0074] Figs. 70 and 71, respectively, are perspective and section views of another connector having a ferrule disposed within a ferrule holder that is loaded from the front end of connector 10 and having an attached SC housing;

[0075] Figure 72 is a perspective view of the connector housing of Figs. 70 and 71;

[0076] Figs. 73 and 74 are cross-sectional views of the connector housing of Figs. 70 and 71;

[0077] Figure 75 is a partially exploded view of the front end of the connector depicted in Figs. 70 and 71;

[0078] Figure 76 is a cross-sectional view of the front end of the connector depicted in Figs. 70 and 71;

[0079] Figure 77 is a perspective view of the splint and splint support of the connector depicted in Figs. 70 and 71;

[0080] Figure 78 is a front view of the connector depicted in Figs. 70 and 71 without the SC housing showing details for retaining the support mount QAOQnn / zznz / Ε / γΐΛΐ of splint;

[0081] Figure 79 is an assembled perspective view of a cable assembly comprising a multi-fiber optical connector comprising a housing with a transition region having a threaded portion;

[0082] Figure 80 is a perspective view of the multifiber optical connector of Fig. 79 with an attached dust cap;

[0083] Figure 81 is an exploded view of the cable assembly having the multi-fiber optical connector of FIG. 79;

[0084] Figs. 82 and 83 respectively are a detailed exploded and assembled view showing a pre-assembly of components of the multi-fiber optical connector of FIG. 79 before the fiber optic cable is passed through the pre-assembly;

[0085] Figure 84 is a perspective view of the fiber optic cable prepared for insertion into the pre-assembly of FIG. 83;

[0086] Figs. 85 and 86 respectively are a perspective view and a cross-sectional view of the fiber optic cable thread through the pre-assembly of FIG. 83;

[0087] Figure 87 represents a perspective view of the assembly of Fig. 83 after a portion of the optical fiber coating is removed in preparation for inserting the optical fiber ends QAOQnn / zznz / Ε / γΐΛΐ in the multi-fiber splint;

[0088] Figs. 88 and 89 respectively are a perspective view and a cross-sectional view of the multifiber ferrule attached to the optical fibers of the optical fiber cable;

[0089] Figure 90 shows the connector housing before connecting it to a multi-fiber connector cable adapter;

[0090] Figs. 91 and 92 show respectively a perspective view and a cross-sectional view of the multifiber connector housing after it has been connected to the cable adapter; and

[0091] Figure 93 represents a perspective view of the assembled multifiber connector after the nozzle has been attached; and

[0092] Figs. 94 and 94A, respectively, are a perspective view and a cross-sectional view of another connector housing comprising a non-round rear portion. DETAILED DESCRIPTION OF THE INVENTION

[0093] The methods of disclosure will now be discussed in detail, examples of which are illustrated in the accompanying drawings. Where possible, similar reference numbers will be used to refer to components or QAOQnn / zznz / Ε / γΐΛΐ similar parts.

[0094] The disclosed concepts advantageously provide fiber optic connectors that allow for optimized manufacturing and assembly, along with easy and intuitive connectivity to other devices, while maintaining a compact indentation. The described fiber optic connectors are explained and represented with several different configurations and various alternative components or optional features that can be incorporated into one or more of the fiber optic connector concepts, which have a coded portion as desired. For illustrative purposes, several different housing variations are described that can be modified for use with connector constructions where the ferrule is loaded from the rear end of the housing or the ferrule is loaded from the front end of the housing. Some configurations can advantageously use fewer parts while providing robust and reliable optical performance.For example, some of the described configurations allow the ferrule to cooperate directly with a housing (e.g., mounted) without using a ferrule holder like conventional fiber optic connectors. Other designs may increase the connector part count for various reasons or could use a ferrule holder if desired.

[0095] In one aspect, fiber optic connectors QAOQnn / zznz / E / γΐΛΐ (hereinafter referred to as the connector) advantageously comprises a housing with a rear portion comprising an encoding portion and a ferrule. The housing provides first connector indentations that interact with other devices to make an optical connection, and several different first connector indentations that can be used with the described connector constructions are disclosed herein. The first connector indentations can be defined by a housing having a rear portion (RP) with an encoding portion and a front portion (FP). The first connector indentations can also be further defined by a transition region (TR) disposed between the rear portion (RP) and the front portion (FP) of the housing.

[0096] In an illustrative example, the housing comprises a rear portion (RP) having a round cross-section (RCS) comprising a coding portion and a front portion having a non-round cross-section (NRCS). The front portion (FP) or the rear portion (RP) of the housing may be further defined in various configurations as described herein, while retaining a portion of the rear portion (RP) with the round cross-section (RCS) and a portion of the front portion (FP) having a non-round cross-section. QAOQnn / zznz / E / γΐΛΐ non-round (NRCS). For clarification, the rear portion (RP), comprising an encoding portion, and the front portion (FP) may have a rectangular cross-section that also provides a first orientation feature for the connectors to align during mating and prevent insertion into an incompatible device or port. The encoding portion of the connector cooperates with an encoder in a complementary port to prevent damage to the port by inhibiting the insertion of an incompatible connector. The encoding portion can also assist the user during blind insertion of the connector into a port to determine the correct rotation orientation when a line of sight is not possible or practical.

[0097] However, other variations of the housings are possible based on the concepts described. As an example of another housing described here for use with the connector constructions described, the housing can be defined as comprising a portion of the back portion (RP) having a polygonal cross-section (PCS) and a portion of the front portion having a non-round cross-section (NRCS). The front portion (FP) or the back portion (RP) of this explanatory housing can be further defined in various configurations as described herein while retaining a portion of the back portion (RP) with the polygonal cross-section (PCS) and a portion of the front portion (FP) having a non-round cross-section (NRCS), as shown in Figures 79 and 79A. By way of example, the polygonal cross-section (PCS) can be a hexagon, a rectangle, a square, or another suitable polygon, as desired.

[0098] The housings described herein define the mating interface for a suitable companion device for mating with the connector, and the described connector indentations are useful for inhibiting insertion into an incompatible port or device and damaging the connector or device, as well as ensuring proper optical operation for the optical connection since the connector and device match. Furthermore, the housings may have features that aid in the correct alignment or orientation of the connector with the companion device, such as markings, encoders, keyways, etc., without significantly changing the primitive form factors of the housings disclosed and claimed herein. By way of example, although a round cross-section may include another feature, such as an encoder or a keyway, it is still considered a round cross-section.In addition, the housing may have other features, such as locking functions to ensure optical coupling with a complementary device or threads. QAOQnn / zznz / E / YiAi to ensure a dust cover. The locking feature can provide a preset holding force of 50 pounds or more with an add-on device.

[0099] The housing indentations described herein may be further defined by other housing geometry. For example, the transition region (TR) disposed between the rear portion (RP) and the front portion (FP). The transition region (TR) may have different configurations according to the concepts described. In one embodiment, the transition region (TR) may comprise a first transition portion (TP1) disposed on a first side of the housing and a second transition portion (TP2) disposed on a second side of the housing. The first transition portion (TP1) and the second transition portion (TP2) may be separated by an offset distance (OD) in the longitudinal direction. However, other embodiments of housings described herein may have all the transition portions of the transition region (TR) aligned along a common transverse plane of the connector, as desired.In other embodiments, the transition region (TR) of the housing may comprise a threaded portion (TP).

[0100] Other variations may further define the accommodation indentations described in this document. By way of example and explanation for their use with the QAOQnn / zznz / E / γΐΛΐ appropriate accommodations described, the first transition portion (TP1) comprises a first ascending dimension (FRD) from the non-round cross section (NRCS) to the round cross section (RCS), and the second transition portion (TP2) comprises a second ascending dimension (SRD) from the non-round cross section (NRCS) to the round cross section (RCS), where the first ascending dimension (FRD) is different from the second ascending dimension (SRD).

[0101] As another example of a non-round cross-section (NRCS) for use with appropriate housings described herein, a portion of the front portion (FP) of the housing having the non-round cross-section (NRCS) comprises a rectangular cross-section with rounded corners (RC). The rectangular cross-section with rounded corners (RC) is a non-round cross-section (NRCS) due to the rectangular cross-section. The rounded corners (RC) may or may not have an outside dimension (OD) similar to the dimension (D) for the round cross-section (RCS). The rounded corners (RC) can provide stability and a snug fit for the mated connector within a port or device when lateral pulling forces are experienced, inhibiting undue optical attenuation by causing the rounded corners to transition from the front portion (FP) to the QAOQnn / zznz / E / γΐΛΐ rear portion (RP). However, other geometry is possible, such as chamfers or similar, as when the rear portion (RP) has a polygon cross-section (PCS).

[0102] The housing indentations described herein may be further defined by other housing geometry. For example, the front portion (FP) of the housing may comprise another cross-sectional portion (ACSP). For clarification, the other cross-sectional portion (ACSP) may comprise an SC indentation. The SC indentation may, in part, be similar to the internal housing of a conventional SC connector. This particular housing indentation is useful to allow the described connectors to be compatible with existing devices or ports using well-established connector indentations, as desired.

[0103] Housings may also define additional features such as a transition region arranged between the rear and front portions, with the transition region comprising an asymmetric transition with respect to a longitudinal axis of the housing. Similarly, other features in the housing may define the housing as asymmetric for orientation or mating with compatible devices or ports.

[0104] Another aspect for some of the connectors The advantageous features described herein comprise one or more characteristics that allow rotation of the ferrule during assembly to adjust the connector and improve optical performance. Some of the connector designs described also offer multi-stage adjustment of the ferrule / assembly or infinite tuning of the ferrule / assembly to any desired rotational position to improve optical performance.

[0105] The concepts described herein are suitable for fabricating both indoor and outdoor fiber optic cable assemblies using the described connectors, such as drop or distribution cables. Furthermore, the described fiber optic connectors may allow the use of one or more additional components to change the connector form factor as defined by the particular housing. By way of example, a conversion housing may cooperate with the connector housing to change the fiber optic connector from the first connector indentations defined by the housing to second connector indentations at least partially defined by the conversion housing. Consequently, the connectors described herein may be converted to be compatible with other well-known commercial connectors for fiber-to-the-home applications, such as an SC connector or a connector OptiTap®, such as those available from Corning Optical Communications of Hickory, NC. Of course, the concepts described herein can be used with other types of fiber optic connectors, whether hardened or not, and are not limited to these particular connector conversions. Likewise, the connector designs described can be hybrid designs with both optical and electrical connectivity. Electrical connectivity can be provided by contacts on or in a portion of the connector housing and can be useful for power or data as desired for applications such as FTTx, 5G networks, industrial applications, or similar. These and other additional concepts are discussed and disclosed in illustrative detail with reference to the figures herein.

[0106] This document describes several different constructions of 100 fiber optic cable assemblies (hereafter referred to as cable assemblies) comprising the 10 connector and variations thereof. The 10 connectors may use any of the suitable housings or different connector constructions as desired and appropriate. For illustrative purposes, see Figs. 2, Figures 2A, 3, and 5-17 describe connectors into which a ferrule 30 is inserted from a rear end 21 of the housing 20, and Figures 19-43 and 46-53 describe connectors into which the ferrule 30 is inserted from a front end 23 of the connector 10. Figure 2A is a representative housing according to the concepts, showing the coding portion 20KP disposed in the rear portion RP of the housing 20. As shown, the coding portion 20KP is a subtractive coding portion of the primitive geometric round shape, such as the female (unlabeled) encoder or keyway shown in Figure 2A. However, the concepts for the housings 20 can be modified to use the described connector designs, and not the entire substrate subtractive portion need be a keyway.For example, the 20KP coding portion can be defined as a cut section from a part of the RP rear portion of the 20 housing, such as cutting one side flat, thus providing a generally D-shaped cross-section to part of the RP rear portion of the 20 housing.

[0107] Figures 4A-4E represent an explanatory housing 20 for analyzing geometry that, in general terms, can be used with any appropriate connector construction, as well as modifying or altering the housing for the desired connector housing design or construction. As shown, housing 20 comprises a keyway portion 20KP. In addition, the dashed line 20KP' illustrates that the coding portion can be formed by cutting a side portion of housing 20, in QAOQnn / zznz / E / γΐΛΐ in place of the keyway shape. The 20KP keyway portion can also extend into the TR transition region. Likewise, housing 20 in Fig. 2A shows the 20KP encoding portion with the threaded transition portion (TP), and the housing can be modified or altered as desired for other housing designs or connector constructions. For example, the 20KP encoding portion can be used with an encoder in the front portion of housing 20. Illustratively, FIG. 73 represents the concept of a 20K male encoder used with the 20KP encoding portion. In this case, the 20K male encoder is aligned with the 20KP encoding portion in the longitudinal direction of the connector. The concepts described herein can also be used with multifiber connectors. Figs.Figures 44 and 45 disclose concepts related to alternative 20L locking features for use with the 20 housings, as applicable. Figures 46–53 describe another 100 cable assembly comprising connector 10 concepts that describe another cable adapter that can be used with the appropriate 10 connectors described herein. Figure 54 represents the connector 10 according to the described concepts having other housing indentations. Figures 56–61 describe 100 cable assemblies comprising connectors 10 having first connector indentations where the connectors QAOQnn / zznz / E / YiAi can be converted into connectors 10' having second connector indentations using a conversion housing 80,82. Figs. 62-69 describe cable assemblies 100 comprising connectors 10 having first connector indentations where the connectors 10 can be converted into connectors 100 ' ' having second connector indentations using a different conversion housing 82. FIGS. 70-78 describe connectors in which the ferrule 30 is disposed within a ferrule holder 49 and is inserted from a front end 23 of the connector 10.

[0108] Figure 2 is a perspective view and Figure 3 is an exploded view of cable assembly 100 having a connector 10 and an optical fiber cable 90 (hereafter referred to as the cable). Figures 15 and 16 are longitudinal sectional views of cable assembly 100 of Figure 2 showing construction details. Figure 2A represents cable assembly 100 having a connector 10 with a housing 20 that is similar to housing 20 for connector 10 in Figure 2, but the housing 20 in Figure 2A is different. 2A has a different TR transition region. Specifically, housing 20 in Fig. 2A has a TR transition region with a threaded portion TP and can be used with the connector constructions described herein as appropriate. QAOQnn / zznz / E / YiAi

[0109] The connector 10 comprises the housing 20 and a ferrule 30. The housing 20 comprises a rear end 21 and a front end 23 with a longitudinal conduit 22 extending from the rear end 21 to the front end 23. As best shown in FIG. 7, the ferrule 30 comprises a fiber hole 32 extending from a rear end 31 to a front end 33. The conduit 22 allows one or more optical fibers of the cable 90 to pass through the housing 20 for insertion into the fiber hole 32 of the ferrule 30 as depicted in FIG. 7. The cable 90 comprises at least one optical fiber 92, one or more resistor components 94, and a cable jacket 98.

[0110] The connector 10 or components of connector 10 as depicted in Figs. 2, 2A, 3, and 5-17 allow the ferrule 30 to be inserted into the housing 20 from the rear end 21 of the housing 20. Specifically, the ferrule 30 is inserted into an opening 21A at the rear end 21 of the housing 20. The housing 20 depicted in Fig. 2A is similar to the housing 20 in Fig. 2, except that it has a different transition region (TR). Specifically, the transition region (TR) of the housing 20 in Fig. 2A comprises a threaded portion; otherwise, the connector concepts are similar to those described herein. The threaded portion (TR) allows for the securing of a suitable dust cap 70 and also permits the conversion of the connector indentations, such as hardened connector indentations, as shown in Figs. 62-69.However, the concepts of the connector constructions inserted in the back can be used with any suitable housing described here.

[0111] As depicted, the connector 10 in FIG. 3 comprises the housing 20, the ferrule sub-assembly 60, and the cable adapter 59. In this embodiment, the ferrule 30 is a portion of the ferrule sub-assembly 60. An opening 21A at the rear end 21 of the housing 20 is dimensioned to receive a portion of the ferrule sub-assembly 60. The ferrule sub-assembly 60 is configured to cooperate with the housing 20 to inhibit rotation of the ferrule sub-assembly 60 relative to the housing 20 when mounted. However, the ferrule sub-assembly 60 can be configured to permit rotation of the ferrule 30 for tuning, as depicted by arrows and angle θ, as desired, before the ferrule sub-assembly 60 is fully seated within the housing 20, as discussed herein.

[0112] The splint sub-assembly 60 also comprises a splint support 40. The splint support 40 can have different configurations as described herein. The splint 30 can be adjusted relative to the housing 20 if desired and can have incremental adjustment. QAOQnn / zznz / E / YiAi are defined based on the ferrule geometry. However, other features or designs described here for the connectors may allow infinite adjustment of the ferrule to any desired rotational position. Adjusting the ferrule 30 allows for improved optical performance by rotating the ferrule so that any eccentricity in the optical fiber, ferrule, or connector rotates to a known rotational or quadrant position uniformly. Consequently, connectors or other mating devices can be tuned to similar relative rotational positions to improve optical performance, such as reducing optical insertion loss due to misalignment of the optical fiber core or similar factors, as understood in the art. The modalities described herein may also have a plurality of interfaces between components to tune the connector as desired.

[0113] The design of connector 10 in Fig. 3 can also advantageously permit multi-stage tuning if desired. The ferrule 30 or other components / assemblies can be adjusted in step increments, such as by quadrants, or adjusted infinitely as desired. By way of example, the ferrule sub-assembly 60 can be configured to allow rotation of the sub-assembly with respect to the cable adapter 59 (or other components) as desired to adjust the ferrule 30 as represented by the arrows and the angle φ as shown. Furthermore, multi-stage tuning can result in infinite tuning, meaning that any desired rotational position is possible for any eccentricity of the fiber core within the ferrule 30.The step or degree of adjustment at the different component interfaces may depend on the particular construction of the splint, the splint support, the cable adapter, or the housing with respect to the allowed rotation and possible rotation increments of the components.

[0114] By way of example, a first tuning stage can be a quadrant-step tuning, and a second tuning stage can be infinite tuning to allow infinite rotation as desired. More specifically, the step adjustment of the first stage can be used for general adjustment of the fiber core eccentricity, such as the desired quadrant, and then the second stage provides infinite adjustment by allowing fine-tuning of the fiber core eccentricity within the quadrant for precise rotational positioning. By way of explanation, infinite tuning can be achieved by rotating one or more components through an angle of ±180 degrees without step increments, allowing any rotational position for ferrule 30. Of course, other tuning schemes are possible using the concepts described here.Similarly, variations of the splint support 40 or splint submount 60 are possible and are described herein for use with any suitable housing 20.

[0115] The connector 10 in Fig. 3 allows the ferrule 30 to be rotated or tuned within the ferrule subassembly 60 as shown. The ferrule 30 can be configured to rotate in either a stepped or infinite rotation, depending on the particular design. For example, the ferrule 30 could have a selectively adjustable surface 36 that is round to provide infinite rotational positioning, or the selectively adjustable surface of the ferrule 30 could comprise a plurality of flat surfaces 36 for stepped tuning, allowing only certain rotation positions. In addition, infinite tuning of the ferrule 30 can be achieved by tuning or rotating it through an angle Θ of +180° with respect to the ferrule carrier 40, if desired. Being able to rotate one or more components in any direction allows for flexibility in adjustment and inhibits excessive twisting of the optical fiber, which is generally undesirable.

[0116] Connector 10 in Fig. 3 also allows rotation of the ferrule holder 40 to fine-tune the ferrule relative to the housing 20, as shown. In this embodiment, the ferrule holder 40 can be adjusted relative to the housing 20 by means of the rotational position of the ferrule holder 40 with respect to the cable adapter 59 or the rotational position of the cable adapter 59 with respect to the housing. Specifically, the ferrule carrier 40 can be adjusted through an angle φ of ±180° with respect to the housing 40 or in stepped increments, such as by using the rotating encoder 41K of the ferrule carrier (Figure 5) or similar, as desired.For example, the rear end of the ferrule bracket 41 may have one or more keys to cooperate with the cable adapter 59 and allow only certain positions for tuning, or the rear end of the ferrule bracket 41 may simply cooperate with the cable adapter 59 to provide infinite rotation positions for tuning. Adjustment details will be discussed in more detail below.

[0117] It is also possible for connector 10 in Fig. 3 to have a third interface for adjustment. Specifically, the cable adapter 59 can be adjustable relative to the rear end 21 of the housing 20. Similar to the rear end of the ferrule carrier 41, a flange portion (unnumbered) of the cable adapter 59 can have one or more keys to cooperate with the rear end 21 of the housing 20 and allow only certain positions for tuning, or the flange portion of the cable adapter 59 can simply cooperate with the rear end 21 of the housing 20 to provide infinite rotational positions for tuning. Thus, connector 10 in Fig. 3 provides several different adjustment options for manufacturing, depending on the desired requirements for the connector.

[0118] Figures 4-4E represent an explanatory housing 20 for connectors and will be described in more detail to explain the concepts and geometry of housings 20 suitable for use with the connector concepts described herein. Although the housing in Figure 4 is a close-up perspective view of the connector 10, which has a different construction than the housing 20 depicted in Figures 2 and 3, the housing 20 in Figure 4 is similar to the connector housing 20 in Figures 2 and 3. Generally speaking, the indentations of the housing 20 in Figure 4 can be used with connector constructions that insert the ferrule 30 from the rear end 21 of the housing 20 or with connector constructions that insert the ferrule 30 from the front end 23 of the housing, with modifications appropriate for the connector construction.Explanation: The longitudinal conduit 22 of the housing 20 may need to be modified for different connector constructions as appropriate. QAOQnn / zznz / E / γΐΛΐ

[0119] The connectors 10 described herein may use any suitable housing 20 with the desired indentations or construction. The description outlines several different housings that may be used with connector constructions as appropriate, and other variations are also possible. Figure 4 depicts the housing 20, and the connectors 10 may use a variety of different variations of the housing shown in FIG. 4 or other housings such as the housing 20 shown in FIG. 54, which has a locking function on a separate component. Similarly, the housing 20 may comprise one or more features for alignment during mating and may also comprise other features for securing or locking the connector in a suitable port or complementary device.Housing 20 has a relatively compact form factor, such as a length L of approximately 40 millimeters (mm) or less and a cross-sectional dimension of approximately 15 mm or less, such as 12 mm or less, but other dimensions suitable for housing are possible.

[0120] Figs. 4A-4D are respective cross-sectional views of the housing in FIG. 4 taken along the respective planes defined by line 4A-4A, line 4B-4B, line 4C-4C and line 4D-4D. Lines 4B-4B and 4C-4C are taken in the same cross-section. QAOQnn / zznz / E / γΐΛΐ Figure 4E is a side view of housing 20 which is similar to the housing 20 shown in FIG. 4, but also includes thread 28 like the housing 20 depicted in Figs. 3 and 4. The threads 28 are arranged on the front FR portion of housing 20 and are discontinuous.

[0121] Housing 20 comprises the rear end 21 and the front end 23 with a longitudinal duct 22 extending from the rear end 21 to the front end as shown in FIG. 4E. The housing 20 of Figs. 4I-4E comprises a portion of the rear portion RP having a round cross-section RCS and a portion of the front portion having a non-round cross-section NRCS. The transition region TR is arranged between the rear portion RP and the front portion FP of the housing 20. The transition region TR comprises a first transition portion TP1 arranged on a first side of the housing and a second transition portion TP2 arranged on a second side of the housing. In this version, the first transition portion TP1 and the second transition portion TP2 are separated by an offset distance OD in the longitudinal direction of the housing 20 as best shown in FIG. 4E.The OD offset distance for the TP transition portion is useful as it allows the connector to fully seat into complementary devices or ports. QAOQnn / zznz / E / γΐΛΐ have the corresponding geometry. However, other 20 housings for the connectors described here can omit the offset distance if desired.

[0122] Housings 20 may also have features or structures suitable for sealing connectors 10. The sealing plane shall be located in a suitable location along the housing 20 to provide adequate environmental protection as required for the desired environment. Illustratively, the housing 20 may include one or more grooves 20G to receive an appropriately sized O-ring 65. Housings 20 may include other features or structures to aid in sealing. For example, the housing 20 may have a surface suitable for receiving a portion of heat shrink tubing 99 or similar material to seal between a portion of the cable 90 and the connector 10. Any heat shrink tubing 99, such as glue-lined heat shrink tubing, may be used. In addition, other structures or features are possible to help provide a robustly sealed cable assembly 100.

[0123] As used herein, the transition region TR is disposed between the rear end 21 and the front end 23 where the housing 20 effects a transformative change in the primitive cross-sectional shapes from a portion of a rear portion RP to a portion of a front portion FP. As used herein, a primitive cross-section means the outer perimeter of the cross-section without regard to internal cross-sectional features. In addition, portions of the cross-sections may include other features that modify the shape of the primitive cross-sections as desired, such as encoding features, a retaining feature, or a locking feature, while still adhering to the concepts of the transition region TR or front / rear portions as described herein.For example, a front portion FP can have rounded corners or chamfered corners while still being a rectangular cross-section.

[0124] In this form of Housing 20, the front portion (FP) of Housing 20 has a rectangular cross-section that provides a first orientation feature for the connectors for alignment during mating and inhibits insertion into a non-compliant device or port. The non-round cross-section NRCS has the rectangular cross-section with a width W1 and a height H1 as shown in FIG. 4B. The rectangular cross-section provides the first orientation feature because the rectangular portion can only be inserted into a compatible device or port in certain orientations due to its rectangular shape, thus inhibiting insertion or incorrect insertion into non-compliant devices or ports.

[0125] As best shown in FIG. 40, housing 20 of Figs. 4A-4E has the first transition portion TP1 comprising a first upward dimension FRD from the non-round cross-section NRCS to the round cross-section ROS, and the second transition portion TP2 comprising a second vertical dimension SRD from the non-round cross-section NRCS to the round cross-section RCS, wherein the first vertical dimension FRD is different from the second vertical dimension SRD. The dimensions of the riser are measured perpendicularly from the midpoint of the chord defined by the surface of the non-round cross-section NCRS as shown in FIG. 4C to the outer surface of the round cross-section RCS.

[0126] The geometry of housing 20 in Figs. 4A-4E also includes the non-round cross-section NRCS comprising a rectangular cross-section having rounded corners (RC), and the rounded corners (RC) are dimensioned to have an outside dimension (OD) similar to the dimension (D) for the round cross-section RCS. The rounded corners (RC) can provide stability and a snug fit for the mated connector 10 within a port or device when subjected to stress. QAOQnn / zznz / E / YiAi lateral pull forces to inhibit undue optical attenuation by making the rounded corners move from the front portion FP to the rear portion RP.

[0127] The front portion FP of the housing 20 shown has more than one primitive cross-sectional shape along its length. Specifically, the front portion FP of the housing 20 in Figs. 4-4E also comprises another cross-sectional portion ACSP. For clarification, the other cross-sectional portion (ACSP) may comprise an SC indentation. The SC indentation may, in part, resemble the internal housing of a conventional SC connector. This particular housing indentation is useful to allow the described connectors to be compatible with existing devices or ports using well-established connector indentations, as desired. Other embodiments may have connectors configured for an LC connector or other known connector indentations, as desired.

[0128] As best shown in Figs. 4 and 4D, the front portion FP of housing 20 may comprise another ACSP cross-section portion with a primitive cross-section that is different from the non-round cross-section NRCS depicted in Fig. 4D. More specifically, the non-round cross-section NRCS changes to another ACSP cross-section portion as shown. As depicted in Fig. 4D, the other cross-section portion comprises a rectangular cross-section with a width W2 that is less than W1 and a height H2 similar to height H1. For example, height H2 may be equal to height H1. In one embodiment, the other ACSP cross-section portion has a primitive cross-section that is similar to a cross-section near a front end of an SC connector.

[0129] Likewise, the rear portion RP may have more than one primitive cross-sectional shape along its length, as desired. In addition, the rear portion RP may include one or more retaining or locking features that alter or modify the cross-section. For example, housing 20 may also include the locking feature 20L so that the connector can be secured in an adapter, port, or other suitable device. For example, the locking features 20L may comprise features integrated into the housing, such as one or more slots, a flange as shown in FIG. 4E and FIG. 45, a scalloped edge as shown in housing 20 of FIG. 3, a reverse bayonet as depicted in FIG. 44, or a ramp with a ledge as shown in FIG. 71.In these examples, the 20L locking features are advantageously integrated into the housing 20 and require no additional components, and can be used with any of the described concepts. In some embodiments, the 20L locking features are subtractive portions of the primitive geometry of the RP back portion, such as a notch in the round RP back portion. Consequently, having the locking features integrated into the housing 20 (e.g., monolithically formed as part of the housing) can enable denser connector assemblies in complementary devices. Furthermore, these locking features integrated into the housing 20 are located behind the sealing location of the connectors 10. For example, the integrated locking features of the housing 20 are arranged behind at least one 20G groove that seats the O-ring 65.The 20L locking features can cooperate with the features of a complementary coupling device to ensure the coupling of connector 10 with the complementary coupling device.

[0130] Housing 20 may also have features that aid in the correct alignment or orientation of the connector with the complementary device, such as markings, encoders, keyways, etc., without changing the primitive form factors of the housings disclosed and claimed herein. In addition, the housing may have other features for mating with a complementary device or threads for securing a dust cap. Figure 2 is a perspective view of connector 10 with a housing 20 similar to the housing 20 shown in Figure 4, but it also includes thread 28 and the 20K encoding feature. Figures 25 and 26 represent a fiber optic connector similar to Figure 20 that has an alternative housing 20A, which can be used with any suitable fiber optic connector described herein. The housing 20 further comprises 20K encoding features. The 20K encoding features have a predetermined location relative to an orientation of the housing 20 to align the housing's form factor with a respective mating device. For example, the housing 20 or the 20L encoding features provide a suitable orientation for connection, which may be desirable for connectors with angled ferrules.In this mode, the 20K encoding features ensure the correct rotational orientation of connector 10 during insertion and coupling with another device.

[0131] In this particular embodiment, the housing 20 is formed monolithically; however, other embodiments may have designs in which the housing is formed from one or more components, as desired. The housing 20 having a plurality of components may be assembled by press-fitting, adhesive, welding, or similar means. For illustrative purposes, Figures 39 and 40 depict a housing 20 having a plurality of components.

[0132] Returning to the description of connector 10 in FIG. 3 and its components, Fig. 5 is an exploded view of the splint subassembly 60 shown in connector 10 of FIG. 3. The splint subassembly 60 can have several different constructions as depicted here and still implement the concepts described. For example, splint subassemblies 60 can use different splint carrier 40 constructions as described or desired while still implementing the concepts described.

[0133] Ferrule 30 is a portion of ferrule subassembly 60. In these embodiments, an opening 21A in the rear end 21 of housing 20 is sized to receive a portion of ferrule subassembly 60. When mounted, ferrule subassembly 60 is configured to cooperate with housing 20 to inhibit rotation of ferrule subassembly 60 relative to housing 20. For example, the ferrule subassembly may have a friction fit or a locking structure that cooperates with the channel 22 of housing 20, inhibiting rotation of ferrule subassembly 60 relative to housing 20. However, in other embodiments, ferrule subassembly 60 may rotate freely for tuning or similar purposes until it is locked in position. QAOQnn / zznz / E / γΐΛΐ regarding accommodation 20 such as with an adhesive or similar.

[0134] As depicted in FIG. 5, the splint subassembly 60 comprises a splint carrier and a spring member 50. Some embodiments of the splint subassembly 60 may omit the spring member 50 and not deflect the splint 30 forward. If a spring member 50 is used, the splint support 40 may further comprise a spring member cavity 46 as shown. As depicted, the spring member cavity 46 may be configured to receive the spring member 50 in a direction transverse to a longitudinal direction of the splint carrier 40 (e.g., transverse to the fiber optic conduit) as indicated by the arrow.

[0135] As shown in FIG. 5, the ferrule support 40 comprises a rear ferrule support end 41, a front ferrule support end 43, and a ferrule support step 42 extending from the rear ferrule support end 41 to the front ferrule support end 43, wherein the ferrule support step 42 comprises a fiber buckling zone 47. The fiber buckling zone allows the optical fiber 92 to move backward during mating without causing undue optical attenuation. In other words, during mating, the ferrule 30 can be pushed slightly backward, causing the optical fiber 92 of the cable 90 to deflect, and to inhibit optical attenuation, the fiber buckling zone 47 is provided to allow fiber movement.

[0136] The splint support 40 can have several different designs. In one embodiment, the splint support comprises a front end 43 of the splint support, the front end 43 of the splint support comprising at least one cantilever portion as shown in FIG. 10. Generally, at least one cantilever portion extends from a medial portion of the splint support and allows mounting of the splint 30 in the splint support 40. At least one of the first cantilever portion 43A can also be configured to cooperate with the housing 20 to inhibit rotation of the splint 39 with respect to housing 20 when the splint submount 60 is fully seated in housing 20, and allows rotation of the splint 30 for fine-tuning when the splint submount 60 is not seated in housing 20.

[0137] By way of explanation and example, the front portion of the longitudinal conduit 22 of the housing 20 can be sized to fit snugly against the shoulders 43S arranged at the front end 43 of the splint carrier, such that one or more of the cantilever portions clamp the splint 30 and inhibit rotation or deflection of at least one cantilever portion, thereby preventing the splint 30 from rotating beyond its desired location. However, the splint carrier or support 40 still allows the splint 30 to float to the desired degree so that it can be translated in the rearward (i.e., z-direction) or XY directions to allow the splint to be moved slightly to the desired location for precise alignment during mating. For example, the splint 30 is skewed and can float on the elastic member.

[0138] The splint support described herein should not be confused with a splint bracket that fixes a conventional splint directly to the splint holder so that there is no appreciable movement between the splint and the splint holder. Conventional connectors allow the entire splint holder / splint assembly to be spring-loaded. On the other hand, modalities such as those depicted in Fig. 3, Fig. 17, and Fig. 21 allow the splint to float without using a splint support. Furthermore, the splint holder / splint assembly is another component interface where tolerance buildup and impact on geometry can occur. Consequently, the connectors described herein can eliminate the conventional splint support along with the expense and manufacturing time required by using a conventional splint support.

[0139] Figure 5 represents the front end of the QAOQnn / zznz / E / γΐΛΐ splint support 43 comprising a first cantilever portion 43A and a second cantilever portion 43B. Figs. 6 and 7 are longitudinal section views of the splint subassembly 60 of FIG. 3 showing design and assembly details. Figs. 8 and 9, respectively, are a perspective view and a close-up perspective view of the splint carrier 40 of Figs. 5-7 depicting details of the splint carrier.

[0140] In this embodiment, at least one of the first cantilever portion 43A or the second cantilever portion 43B is configured to cooperate with the housing 20 to inhibit rotation of the splint 30 with respect to the housing 20 when the splint subassembly 60 is fully seated in the housing 20, and to permit rotation of the splint 30 for fine-tuning when the splint subassembly is not seated in the housing 20. For clarification, the front end 43 of the splint carrier of FIG.5 can be sized to cooperate with the housing 20 by fitting into a conduit 22 that inhibits the cantilevered portions 43A, 43B from deflecting outwards, thereby inhibiting the rotation of the splint 30 with respect to the splint carrier 40 when the front end of the splint carrier 43 is fully seated in the housing 20 since some of the selectively adjustable surfaces 36 (in this case the flat surfaces 36S) of the splint 30 cooperate with it. QAOQnn / zznz / E / γΐΛΐ splint retention structure 43C of splint carrier 4 0.

[0141] The splint subassembly 60 is assembled by placing the elastic member 50 into the cavity 46 of the elastic member, inserting the spring in the direction transverse to the splint-carrying conduit, as best shown in FIG. 5. The splint support 40 of FIG. 5 allows the splint 30 to be inserted from the front end 43 of the splint support, as represented by the arrow. When the splint 30 is inserted into the front end of the splint support 43, the first cantilever portion 43A and the second cantilever portion 43B are deflected outward, as represented by the arrows shown in FIG. 6. As the splint 30 seats on the front end 43 of the splint support, the first cantilever portion 43A and the second cantilever portion 43B spring back into their original positions to capture the splint 30. As best shown in Figs.7 and 9, one of the first cantilever portions 43A or the second cantilever portions 43B comprise a splint retention structure 43C. Consequently, when the first and second cantilever portions 43A, 43B are inhibited from deflection, then the rotation of the splint 30 is inhibited, as when the splint subassembly 60 is fully seated within the housing 20. However, when the first and second cantilever portions 43A, 43B can be... QAOQnn / zznz / E / YiAi deflect outwards, as shown in FIG. 6, then the splint 30 can be rotated through any desired angle θ for tuning.

[0142] Furthermore, the rear end of the ferrule carrier 40 may have other features that allow for tuning if desired. For example, the rear end of the ferrule holder 41 may have a ferrule support groove 41G or a protrusion to cooperate with the cable adapter 59, thereby permitting rotation between the two components in stepped or infinite increments as desired and discussed herein. By way of example, the ferrule holder 40 may comprise one or more ferrule support pivot keys 41K to permit rotational step increments, or the ferrule holder 40 may omit the ferrule support pivot keys 41K and permit infinite rotational positions with respect to the cable adapter 59, which may be fitted into the rear end 21 of the housing 20. The ferrule holder 40 may be attached to the cable adapter in any suitable manner, such as by adhesive, soldering, mechanical fitting, etc.

[0143] Other embodiments may integrate the ferrule support 40 and the cable adapter 59 into a monolithic component. However, the use of a separate cable adapter 59 allows the connectors 10 to accommodate different cables, such as round, flat, or of different sizes, simply by selecting the appropriate size cable adapter 59 for the desired cable type. Furthermore, the cable adapter may include one or more flexes 59F on the rear portion to provide cable bending stress relief if desired, instead of using a conventional sleeve. The flexes shown are suitable for flat cables that have a preferential bending characteristic.

[0144] Again, the connectors described herein allow the ferrule 30 to have a small amount of float within the ferrule carrier or housing without using a ferrule support like conventional fiber optic connectors. Conventional connectors mount the ferrule within a ferrule support in a fixed position, and then the ferrule support is typically spring-loaded. On the other hand, some of the connector designs described in this application have the elastic member 50 that directly deflects the ferrule, eliminating parts and also allowing greater flexibility for ferrule selection or adjustment. Furthermore, the ferrule can be adjusted relative to the ferrule support or housing, depending on the connector design. In addition, the high-precision geometry ferrule support is eliminated, along with the tolerance buildup, by using a conventional connector with a ferrule support.However, the accommodation concepts described in this document may vary. QAOQnn / zznz / E / γΐΛΐ to be used with connectors that have splint supports as described in Figs. 70-78.

[0145] The retention structure of splint 43C is configured to cooperate with the geometry of splint 30. Specifically, the splint 30 depicted in FIG. 5 has at least one selectively adjustable surface 36 that cooperates with the retention structure of splint 43C. The retention structure of splint 43C is dimensioned to fit snugly onto one or more selectively adjustable surfaces 36 of splint 30 as shown in FIG. 7. However, when the splint holder 40 is not seated in the housing 20, splint 30 can be rotated within the splint holder 40 around an angle Θ to optically adjust the assembly. The splint 30 may have a selectively adjustable round surface 36 for infinite tuning, but that requires a tight fit between the front end of the splint carrier 43 and the appropriate part of the conduit 22 of the housing 20.If the splint 30 uses selectively adjustable surfaces 36 comprising a plurality of flat surfaces 36S, then the appropriate portion of the conduit 22 simply has to inhibit the deflection of at least one cantilever arm so that the splint 30 is inhibited from rotation when fully assembled. Figs. 8 and 9 represent detailed views of the splint carrier 40 of Fig. 5. As shown. QAOQnn / zznz / E / YiAi shows, the first and second cantilever portions 43A, 43B of the splint carrier 40 may have lowered the forward portions of the shoulder 43S, thereby allowing robust seating and inhibiting deviation of the cantilever arms 43A, 43B.

[0146] The ferrule 30 can have any suitable number of 36S flat surfaces, as desired. For example, four 36S flat surfaces allow for quadrant tuning, and additional flat surfaces allow for finer tuning in a first stage. However, ferrules 30 can have any number of flat surfaces as desired, such as six or eight, to increase the number of steps for adjusting the ferrule. Generally speaking, quadrant tuning is sufficient, and if combined with a second-stage infinite tuning interface, the connector can be advantageously tuned to any desired rotational position quickly and easily during manufacturing.

[0147] Figure 10 is a perspective view of an alternative splint support 40' that can be used in splint subassembly 60, and Figures 11 and 12 are, respectively, a partially exploded view and an assembled view of the alternative splint support 40' in splint subassembly 60. This splint support 40' is similar to the support 40 of QAOQnn / zznz / E / γΐΛΐ splint, but only has the first arm cantilevered and requires the loading of splint 30 from the transverse direction as the elastic member 50. Splint 30 can still be rotated with respect to the splint carrier 40', but may require a slightly greater rotational force to deflect the U-shaped portion or a slight upward translation of splint 30 to help reduce the rotational force required for rotation.

[0148] Figures 13 and 14 are, respectively, a partial sectional view and a cross-sectional view of the alternative ferrule holder of Figures 10-12, shown mounted on the ferrule subassembly 60 and arranged in the fiber optic connector housing 20. As shown, the conduit 22 of the housing 20 may include a different geometry to seat the ferrule subassembly 60 within the housing and inhibit rotation of the ferrule 30 relative to the housing 20 using the alternative ferrule holder 40'. As shown, the housing 20 comprises a conduit 22 with an internal encoder 20KI that cooperates with the U-shaped portion of the alternative ferrule holder 40'. Consequently, the alternative ferrule holder is inhibited from further rotation with respect to the housing 20.

[0149] Figure 17 is an exploded view of another cable assembly 100 that is similar to the cable assembly 100 of Figure 2 shows a fiber optic connector having a different ferrule subassembly 60, and Figure 18 is a partially exploded view of the cable assembly 100 of Figure 17 with the fiber optic cable attached to the ferrule subassembly 60. This cable assembly 100 comprises a connector 10 having a ferrule support 40 that is monolithically formed with the cable adapter as shown. Otherwise, the cable assembly 100 is similar to the cable assembly 100 of Figure 2.

[0150] The concepts described here can be used with other connector types and designs. For example, Figures 19-43 and 46-53 depict connectors in which the splint 30 is inserted from a front end 23 of the connector 10. These connector designs are shown without a splint carrier as generally described herein, but can be used with a splint carrier if desired. These connector designs differ from the previous connector designs in that they do not use a splint carrier; however, these designs can still be optically adjusted if desired. Specifically, these connector designs comprise a splint 30 that floats relative to the housing 20 and use a different structure to secure the splint while allowing it to float.Any suitable housing 20 as described in this document may be used for these connectors provided they are appropriately modified to secure the splint 30 as described in more detail below.

[0151] For illustration, Figs. 19 and 20 are perspective views of cable assembly 100 having a different fiber optic connector 10 with housing 20 that is similar to the housing shown with the fiber optic connector in Fig. 2, but which has a ferrule 30 that is loaded from the front end 23 of the housing 20 and secures a transverse ferrule retaining member 140. Fig. 21 is an exploded view of another cable assembly 100, which is similar to that in Fig. 19, with the connector having a housing that has discontinuous threads. Fig. 22 is an assembled perspective view of the cable assembly 100 of Fig. 21, and Fig. 23 is a perspective view of the cable assembly 100 of Fig. 22 with a dust boot 70 installed. Figure 24 is a longitudinal sectional view of the cable assembly 100 of Fig. 22 in the vertical direction and Fig.Figure 29 is a longitudinal cross-sectional view of a front portion of the 100 fiber optic connector in a horizontal direction.

[0152] With reference to FIG. 21, the connector 10 comprises the housing 20, the ferrule 30, and the transverse ferrule retaining member 140. The housing 20 is similar to the other housings described herein, but further comprises an opening 129 in an outer surface that is transverse. QAOQnn / zznz / E / γΐΛΐ to the longitudinal conduit 22 of the housing 20. The opening 129 is dimensioned to receive the transverse ferrule retaining member 140 and to secure the ferrule 30 in a manner that permits adequate movement so that it may float as appropriate as depicted in FIG. 24. The connector 10 may also comprise a band 69 for securing a cable 90 to the connector if desired.

[0153] Figure 25 is a detailed exploded view of the front end of the cable assembly 100 of FIG. 22 and Fig. 26 is a cross-sectional view taken in the opening 129 of the housing 20 of Fig. 19 showing the transverse ferrule retaining member 140 securing the ferrule 30. As depicted in FIG. 25, the splint 30 is loaded into the channel 22 of the housing 20 from the front end 23 and secured by the cooperation of the splint 30 with the transverse splint retaining member 140, which is inserted into the opening 129 to cooperate with at least one surface of the splint 30. Specifically, the splint 30 is inserted into the channel 22 until the cooperating surface, such as a retaining feature of the splint, aligns with the opening 129 so that the transverse splint retaining member 140 can engage the surface and secure the splint.In addition, at least one surface of splint 30 that serves as a splint retention feature cooperates with splint retention member 140. The transverse QAOQnn / zznz / E / γΐΛΐ is dimensioned in relation to the transverse splint retaining member so that the splint 30 can float. The splint retaining feature can also be the same feature as at least one selectively adjustable surface 36.

[0154] In this embodiment, the splint has at least one selectively adjustable surface 36, such that the splint 30 can have at least two rotational orientations with respect to the housing 20 (and which acts as the retaining feature of the splint). However, the splints 30 can have any suitable number of selectively adjustable surfaces 36, so that the splint 30 can have the desired number of rotational positions for adjusting the splint. By way of example, the splint can have four, six, eight, or any suitable number of selectively adjustable surfaces 36, as desired. More specifically, the longitudinal channel 22 of the housing 20, extending from the rear end 21 to the front end 23, also comprises a tuning cavity 24 in cooperation with the longitudinal channel 22. The tuning cavity 24 allows rotation or manipulation of the splint 30 within the housing as required.In this embodiment, the transverse splint retention member 140 is secured to the housing 20 using a pair of fasteners 140C arranged on the arms of the retention member 140. QAOQnn / zznz / E / γΐΛΐ transverse splint. The 140C catches can be press-fitted into portions of the housing 20 arranged in the opening 129 such ledges. However, other variations are possible for securing the splint 30. By way of example, Figs. 27 and 28 respectively represent a detailed view of an alternative transverse splint retaining member 140 having catches 140C and a cross-sectional view showing the alternative transverse splint retaining member 140 for securing the splint 130. As best illustrated in Fig. 27, the catches 140C are arranged on a medial portion of the arms of this alternative transverse splint retaining member 140. Accordingly, the catches 140C cooperate with a portion of the splint 30 as depicted in Fig. 28, instead of accommodation 20 as depicted in FIG. 26. FIG.Figure 29 is a cross-sectional view of a portion 20 of the housing having an opening width 129 greater than the width of the cross-splint retaining member 140 so that the splint 30 can float. Figure 30 is a cross-sectional view representing the tuning cavity 24 of the housing 20, which allows rotational tuning of the splint 30 during manufacturing to improve optical performance. Specifically, when the cross-splint retaining member 140 is disengaged, the splint 30 can be rotated relative to the housing. As shown, the tuning cavity 24 allows the splint 30 to be rotated through an angle Θ suitable for optical tuning to a preferred rotational position represented by the arrow. For example, the splint 30 can be rotated through an angle θ of ±180 degrees, but other suitable angles are possible.

[0155] Figures 31 and 32 represent explanatory splints 30 having at least one selectively adjustable surface 36. Figure 31 shows a quadrant-tuned splint with four selectively adjustable surfaces 36. Generally speaking, the selectively adjustable surfaces 36 are configured as flat surfaces, as shown. More specifically, the selectively adjustable surfaces 36 are formed by a plurality of flat surfaces embedded in the splint 30. Finer tuning is possible by having more selectively adjustable surfaces, such as six, eight, ten, or twelve, thus providing more rotation positions for securing the splint 30.Figure 32 depicts a splint 30 where selectively adjustable surfaces 36 are arranged adjacent to a freely rotating portion 36A of the splint 30, thereby permitting rotation of the splint for adjustment during assembly without removing the transverse splint retaining member 140. For clarification, the splint 30 in Fig. 32 can be secured by the transverse retaining member 140. QAOQnn / zznz / E / YiAi a rotational adjustment is required, then the splint 30 can be moved back until the free-rotating portion 36A is aligned with the transverse retaining member 140, allowing rotation of the splint in any direction. When the desired rotational position is reached, the splint 30 is allowed to move to the forward position where the selectively adjustable portions 36 engage and cooperate with the transverse splint retaining member 140 to inhibit rotation of the splint 30. Consequently, the transverse splint retaining member 140 does not need to be removed from the housing 20 for tuning.

[0156] Figs. 33-36 are various views representing the housing 20 of connector 10 of FIG. 23 comprising the opening 129 and the adjustment pocket 24. As shown, the housing 20 is similar to the other housings and can be modified for the desired housing configuration as required. For example, although the housing 20 represents threads 28 that are discontinuous for joining the dust cap 70 as shown in FIG. 23, variations are possible that eliminate the threads 28 and use a snap-on dust cap. Likewise, other variations of the housing 20 are possible, such as changing the mating geometry and using the concepts described with the mating geometry of the housing 20 represented in FIG. 54. In addition, the housings 20 can have different retention characteristics or different locking characteristics. For comparison, the housing 20 of Fig.3 comprises a locking feature 20L disposed between the rear end 21 and a front end 23 configured as a festoon, and the locking feature 20L of the housing of FIG. 4 is configured by a shoulder. The shoulder comprises an enlarged annular portion 126 with a flat surface on the rear side.

[0157] By way of example, FIG. 37 is a perspective view of another cable assembly 100 with yet another alternative connector 10 that is similar to the connector 10 of FIG. 19, but further comprises a multi-piece housing 20 comprising a nozzle 160. FIG. 38 is a perspective view of the cable assembly 100 with dust cap 70 and FIG. 39 is an exploded view of the cable assembly 100.

[0158] As best described in FIG. 39, the connector 10 comprises a housing 20 having a nozzle that fits around a front end 23. In this configuration, the use of the separate nozzle 160 provides more access to the conduit 22 of the housing and allows more space and visibility for assembly. In addition, the opening 129 is arranged in a location that is covered by the nozzle 160, so that once the connector is tuned and QAOQnn / zznz / E / γΐΛΐ The nozzle 160 is secured, and the cross ferrule retaining member is neither visible nor accessible. The housing 20 of this embodiment also has a different locking feature 20L compared to the housing depicted in FIG. 33-36 and an opening 29. The locking features 20L are configured as a slot to receive a clip or other suitable locking feature from an accessory device to retain the connector in a mated state when secured. This embodiment of the connector also uses the cable adapter 59, so that the connector can accommodate different types of cable using the appropriately sized cable adapter 90 for the given cable.

[0159] Figure 40 is a front sectional view of connector 10 from Fig. 37 showing nozzle 160 attached to the front end of housing 20, and Fig. 41 is a front view of the housing showing a joining interface (unnumbered) such as a solder interface disposed on a front portion of housing 20. As depicted in Fig. 40, once nozzle 160 is installed, it inhibits the removal of the cross ferrule retaining member 140. In other words, the cross ferrule retaining member 140 is neither visible nor accessible once the nozzle is installed. Consequently, once the connector is tuned and the nozzle is installed... QAOQnn / zznz / E / γΐΛΐ In a suitable manner, the transverse retaining member of the ferrule 140 is tamper-resistant. The housing's attachment interface provides a surface for bonding the nozzle 160. The nozzle 160 can be attached in any suitable manner, such as by adhesive, friction fit, press fit, welding, or similar methods, as desired. In one embodiment, the nozzle 160 is formed from a translucent material. The use of a translucent material for the nozzle 160 allows the use of a UV-curable epoxy to secure the nozzle 160.

[0160] Further connector variations using modified housings or other modified components are still possible. Figures 42 and 43 are perspective and side views of a connector 10 similar to Figure 37 that has an alternative housing 20. The housing 20 in this embodiment has no offset distance between the transition portions TP1-TP4. In other words, all transition portions TP1-TP4 are aligned. Furthermore, this housing 20 incorporates the 20K encoding feature for orienting the connector for mating. The 20K encoding feature is an encoder, but other embodiments may use another suitable structure such as a keyway or similar.

[0161] Other variations of the housings described herein are also possible, such as having other shapes for the rear portion RP, such as a polygonal cross-section PCS instead of the round cross-section RCS. The polygonal cross-sections can have any suitable number of sides, such as four, five, six, seven, or eight, but other suitable numbers of sides are also possible. Still more variations on the described housing concepts are possible. For example, the connector housing 20 can be configured to work with other devices such that a retention or locking feature of the connector is intended to cooperate with different devices to maintain the optical connection at the mating interface. As an example, Figures 44 and 45 are perspective views of parts of alternative housings 20 that represent other locking feature designs.The 20 housings shown in Figs. 44 and 45 can be used with any suitable connector described in this document. Similarly, the locking or retaining functions can be selected in conjunction with other functions, such as the 20K encoding features. The 20K encoding features have a predetermined location relative to a 20 housing orientation to align the connector's form factor with a respective mating device. Specifically, the 20 housing provides a suitable orientation for connection in a certain orientation. QAOQnn / zznz / E / γΐΛΐ may be desired for angled splints. In this configuration, the 20K encoding features are arranged on a center line of the 10-fiber optic connector and ensure correct rotational orientation during insertion and coupling with another device.

[0162] The components or features of the connectors can be selected as desired to form other connector variations. Illustratively, FIG. 46 is a perspective view of another cable assembly 100 that uses a connector similar to the connector in FIG. 37, but has a different cable adapter 59. The connector also has a different type of locking feature 20L than the housing 20 of the connector in FIG. 37. Like the cable adapter 59 in FIG. 37, the cable adapter 59 of this embodiment fits into a rear opening 21A of the housing 20. As discussed, the use of connectors with a separate cable adapter 59 allows the connector to be used with different types of cables simply by changing and selecting the cable adapter that is suitable for the desired cable 90. Figures 47 and 48 are, respectively, a perspective view and a cross-sectional view of the cable adapter 59 of FIG. 46.Fig. 49 is a vertical cross-sectional view and Fig. 50 is a horizontal cross-sectional view of the rear portion of cable assembly 100 showing cable 90 arranged inside cable adapter 59. QAOQnn / zznz / E / γΐΛΐ

[0163] Figures 47A and 48A are a perspective view and a cross-sectional view of another cable adapter 59, which is similar to the cable adapter in Figure 47. As shown, cable adapters 59 may comprise an opening 59A, a recessed surface 59R, a flange 59S, a conduit 59P, and a cable support 59C or a cable adapter encoder 59K, as desired for any particular modality of cable adapter 59. Generally speaking, the cable adapter 59 comprises the passage 59P from a front end of the cable adapter 59F to a rear end of the cable adapter 59R. The conduit 59P allows the optical fiber 92 of the cable 90 to pass through it. The 59S shoulder allows the cable adapter 59 to fit snugly inside the duct 22 of the housing 20 and prevents the adhesive from being absorbed or flowing forward from the 59S shoulder.Any adhesive or epoxy used to secure the cable adapter 59 can be moved around the recessed surface 59R to create a sufficient bonding area, and any excess adhesive or epoxy can flow into the opening 59A. The housings 20 may include one or more openings 29 for injecting epoxy or adhesive, or the adhesive or epoxy may be placed on the cable adapter before insertion into the housing. For example, the housing may include two openings 29, as shown in FIG. 49, to allow air to escape. QAOQnn / zznz / E / γΐΛΐ when adhesive or epoxy is injected. In addition, one or more openings 29 can be aligned with the openings 59A of the cable adapter so that the adhesive or epoxy also secures the strength members 94 of the cable 90 to the cable adapter 59, which is secured to the housing 20, thus forming a robust cable / connector connection and also providing a seal at the rear end. The cable holder 59C is sized and shaped to the particular cable 90 that is intended to be secured using the cable adapter together with appropriate components as applicable, as shown in FIG. 50. The rear of the cable adapter 59 can have a cable bend relief area, such as a reverse funnel at the conduit entrance, bends, or other suitable structure to inhibit abrupt bending of the cable near the rear of the cable adapter 59.Furthermore, the cable adapters 59 may or may not include 59K encoders as desired to cooperate with the housing characteristics. The rear portion 59R of the cable adapter 59 of FIG. 47A comprises one or more 59RB ribs suitable for receiving a sleeve or overmolding on the rear portion 59R. The 59RB ribs help to retain the sleeve or overmolding.

[0164] Figure 51 is a perspective view of another cable assembly 100 according to the concepts described, and FIG. 52 is an exploded view of assembly 100. QAOQnn / zznz / E / γΐΛΐ of cable. Housing 20 of this embodiment is similar to the housing described herein, but further comprises a 20KP encoding portion extending into the TR transition region as shown, although embodiments without the 20KP encoding portion are possible. The TR transition region of this housing is asymmetrical. Specifically, the asymmetrical transition region is a threaded portion TP, but other asymmetrical geometries are possible as described herein. In this embodiment, the 20KP encoding portion is configured as a female encoder or a subtractive portion in housing 20, such as a female groove or a cut in the side of the connector leaving a D-shape. The 20KP encoding portion extends into the transition region as shown.The 20KP coding portion cooperates with a suitable coding or keying part in a device connection port, such as an additive or male part, to inhibit the insertion of non-conforming connectors into the connection port. Although the 20KP coding or keying portion is arranged at approximately 180 degrees from at least one 20L locking feature, other arrangements are possible where the 20KP coding portion is arranged at less than 180 degrees from at least one 20L locking feature. In other embodiments, the 20KP coding or keying portion may be arranged as a subtractive portion that removes one side or cut of the 20 housing to create a D-shaped cross-section along the 20KP coding portion, instead of the female keyway shown.

[0165] The internal construction of the connector 10 of Fig. 52 is similar to that of Figs. 70-78, where the ferrule 30 is disposed within a ferrule support 49 and is inserted from a front end 23 of the connector 10, and is discussed in more detail in relation to those figures. This embodiment also comprises a sleeve or overmolding 259 disposed on the rear portion 59R of the cable adapter 59, as best shown in Fig. 53. Furthermore, when a sealing element is mounted, such heat shrink tubing 99 is disposed on the sleeve or overmolding 259, as best shown in Fig. 54. The sealing element may also be disposed on a portion 20 of the housing, as shown. Placing the sealing element on the sleeve or overmolding and a portion 20 of the housing allows the cable jacket to be sealed at the rear of the connector. This may also improve flex strain relief for cable assembly.

[0166] Figure 51A is a rear perspective view of another cable assembly having a cable adapter 59 with flexures 59F for flex strain relief. Figures 52A and 53A are side and section views of the cable assembly of FIG. 51A showing the heat shrink tubing 99 before QAOQnn / zznz / E / YiAi and after installation. As shown, if the cable adapter 59 uses bends 59F, they are generally aligned with the flat portions of the cable 90 for cable bend relief. In addition, the cable adapter 59 may or may not have more than one rotational position with respect to the housing 20, depending on how the component ends cooperate. As depicted in FIG. 53A, the housing 20 may have a stepped portion at the rear end 21 to receive a heat-shrink portion 99 and may cover the bends 59F while also providing greater cable bend stress relief.

[0167] Other variations of the 20 housings are still possible using the connector concepts described here. The other connector modalities described include 20L locking features that are integrated into the 20 housing; however, other connectors may use locking features that are separate components, distinct from the 20 housing. Although this may require larger connector indentations or more access space between connectors, separate component concepts for the locking features are possible. Figure 54A is a perspective front view of another 20 housing that can be used with the fiber optic connector concepts described here. In this modality, the QAOQnn / zznz / E / YiAi The locking feature is formed on a separate component distinct from the housing 20. Specifically, the locking feature is arranged on a coupling nut 120 that has threads and rotates about an external axis of the housing 20 to secure the connector to a complementary device. Furthermore, the housing 20 may not have an offset distance between the transition portions of the housing 20, as depicted in this embodiment.

[0168] The connectors described herein may be portions of other cable assemblies as desired. For example, Fig. 55 represents a 100' distribution cable having one or more connectors 10 on the 90' ​​tie wires extending from a mid-rung access 93 of a distribution cable. Of course, other suitable assemblies may use the connectors in accordance with the concepts described herein.

[0169] By way of example, the connectors described herein can be converted from first connector indentations to second connector indentations. Figure 56 is a perspective view of an explanatory connector 10' comprising further a conversion housing 80 joined around the housing 20 to change the connector 10' from first connector indentations to second connector indentations, and Figure 57 is a cross-sectional view of the connector 10'. By way of example, the connector 10' can have first connector indentations as shown in Figure 19 and be changed to second connector indentations such as an SC connector by adding the conversion housing 80. However, any of the suitable connectors described herein can be converted as described herein.The conversion slot 80 cooperates with slot 20 to change from the indentation of the first connector to the indentation of the second connector. In this mode, the change from the indentation of the first connector to the indentation of the second connector involves the use of a single component.

[0170] In other embodiments, changing the indentations of the first connector to the indentations of the second connector may involve the use of a plurality of components. Illustratively, FIG. 58 is a partially exploded view of another connector 100' that can be changed from a cable assembly 100 having first connector indentations 10 to second connector indentations 10' as shown assembled in FIG. 59. Furthermore, this embodiment of second connector indentations 10' comprises hardened connector indentations. Hardened connector indentations mean that the connector is suitable for outdoor environments without being protected within an enclosure. Any suitable connector 10 described herein may be used for such a conversion from first to second indentations.Figure 58 depicts cable assembly 100 with connector 10, showing the plurality of components for conversion to the second type. The indentations are used to illustrate the component assembly. In this particular embodiment, the plurality of components is suitable for converting connector 10 into a hardened OptiTap®-compatible connector; however, the plurality of components can be configured to convert connector 10 into other hardened connectors as required. In this embodiment, the plurality of components for conversion to the hardened connector comprises an inner sleeve 83, an outer sleeve 87, a conversion housing 82 configured as a cover, a retaining member 84 configured as a retaining nut, and a coupling nut 85.To convert to the hardened connector, the inner sleeve 83 slides up over a portion of the connector 10, and the conversion housing or cover 82 slides back into position. The retaining nut 84 is then secured to the threads of the connector 10. The mating nut 85 slides over the cover 82, and the outer sleeve 87 can then be slid up into position from the rear. The cover 82 may include an O-ring 86 for sealing during mating. Figure 60 is an assembled view of the fiber optic connector of Fig. 58, showing the indentations of the second hardened connector with the dust cap 88 installed. Figure 61 is a cross-sectional view of the hardened connector of Fig. 60.

[0171] Other methods for converting connectors 10 are still possible, in accordance with the concepts described herein. For example, connectors 10 similar to connector 10 in FIG. 2A, with the transition region TR having a threaded portion TP, can be converted to other connectors. Figure 62 depicts cable assembly 100 having a connector 10 with a connector housing 20 comprising a transition region TR having a threaded portion TP similar to connector 10 in FIG. 2A. Figure 63 shows the connector 10 of Fig. 62 with a conversion housing 82 attached around the housing 20 to change the connector 10 with first connector indentations to a connector 10'' with second connector indentations. The second connector indentations for the 10'' connector comprise hardened connector indentations, thereby converting cable assembly 100 into cable assembly 100''.

[0172] Figure 64 is a partially exploded view of the 10" connector of FIG. 63. This particular conversion uses a plurality of components to convert the 10" connector into a reinforced OptiTap® 10" compatible connector; however, the plurality of QAOQnn / zznz / E / γΐΛΐ components can be configured to convert connector 10 into other hardened connectors, as desired. The plurality of components for conversion to connector 10 comprises the conversion housing 82 configured as a cover, a retaining member 84 configured as a retaining clip, and a mating nut 85. The cover 82 may include one or more tonic gaskets 86 for sealing during mating with a complementary device.

[0173] To convert to connector 10, cover 82 is slid into a channel of the coupling nut 85 as shown and then slid onto connector 10 from the front end. Cover 82 is then rotated so that the internal threads 82T of cover 82, as best shown in FIG. 65, engage with the threaded portion TP of connector 10 until cover 82 is secured to connector 10. Retaining member 84 is then aligned with the front end of cover 82 and pushed onto connector 10 until it seats and is retained in the housing 20, thus preventing cover 82 from retracting from the threaded portion TP of connector 10, as shown in Figure 66.

[0174] Figure 67 is a detailed sectional view of the front end of connector 10 showing the retaining member 84 secured to the connector 10, and Figures 68 and 69 are perspective views of the retaining member 84. As shown, the retaining member 84 comprises an opening 840 in the front portion to receive a portion 20 of the housing through it when installed. In addition, the retaining member 84 also has a front flange 84F shaped to the conduit of the cover 82 so that it can be inserted into and engage the connector 10. The retaining member 84 may also include one or more keys 84K to allow the retaining member to slide past the coding feature 20K of the connector 10. Windows 84W arranged on opposite sides of the retaining member 84 engage with the lugs 27 of the housing 20 to secure the retaining member 84 to the connector 10.Once installed, the retaining member 84 prevents the cover 82 from rotating and coming off the connector 10. The connector 100' may also include a dust cap 88 like the connector 10' in FIG. 60.

[0175] The connector concepts described herein may be used with other connector designs, such as connectors using a ferrule disposed in a ferrule holder. Figures 70-78 describe a cable assembly 100 comprising the connector 10. The connector 10 of Figures 70-78 is similar to other connectors 10 described herein, but has a ferrule 30 disposed within a ferrule holder 49 and inserted from a front end 23 of the connector 10 as depicted in Figure 75. The housing 20 of the connector 10 of Figures 70-78 is similar to other housings 20 discussed herein, and the differences will be described, while other details will not be repeated for the sake of brevity.

[0176] Figs. 70 and 71, respectively, are perspective and section views showing the cable assembly 100 comprising the connector 10 having a ferrule 30 disposed within a ferrule support 49, thereby forming a ferrule sub-assembly (not numbered) that is tilted to a front position by the elastic member 50. When assembled, the ferrule sub-assembly (60) is configured to cooperate with the housing (20) to inhibit rotation of the ferrule sub-assembly (60) with respect to the housing (20) as best shown in FIG. 78.

[0177] As shown in FIG. 70, connector 10 is configured so that the conversion housing 80 can be attached to housing 20 to convert it into an SC connector. Connector 10 also has a housing 20 with a transition region TR and a threaded portion TP similar to the housing 20 shown in FIG. 2A so that it can be converted into a hardened connector as shown in Figs. 62-69.

[0178] Figs. 72-74 are various views of the housing 20 of connector 10 depicted in Figs. 70 and 71. Fig. 72A is a bottom perspective view showing the locking features 20L of housing 20 QAOQnn / zznz / E / γΐΛΐ configured as a ramp (unnumbered) with a ledge (unnumbered) as the retaining feature to cooperate with a suitable safety feature of a device. Housing 20 is similar to the housings 20 described herein, but further comprises one or more latching arms 20LA arranged in a front portion FP of the housing 20 as depicted. In addition, the front opening of the conduit 22 is dimensioned to permit insertion of the ferrule support 49 from the front end 23 of the housing 20 as shown in the cross section of FIG. 73. The latching arms 20LA are connected at the front end and cantilevered at the rear end so that they can deflect when the ferrule support 49 is inserted and then retract to retain the ferrule support 49 once it is fully inserted.

[0179] Figure 75 is a partially exploded view of the front end of connector 10 before the ferrule support 49 and ferrule 30 are inserted into the housing 20. Figure 76 is a cross-sectional view of the front end of connector 10 after the ferrule support 49 and ferrule 30 are inserted into the housing 20 and retained by the latching arms 20LA. As shown, the latching arms 20LA have ramp portions to assist the portions of the ferrule support 49 in deflecting the latching arms 20LA outward as QAOQnn / zznz / E / γΐΛΐ The splint support 49 is inserted into housing 20 and then retracts over the splint support 49 to retain it.

[0180] With reference to FIG. 75, the optical fiber 92 of cable 90 is mounted to extend beyond the front end 23, and the elastic member 50 is wound around the optical fiber 92. Then the ferrule support 49 and ferrule 30 are screwed onto the optical fiber 92. The optical fiber 92 can be properly secured through the holes 20C arranged on the opposite side of the housing 20, as represented by the arrows in FIG. 76, when the ferrule support 49 is inserted into the housing 20. Securing the optical fiber 92 prevents it from pushing back or bending when the ferrule support 49 is inserted. The splint support 49 is aligned to a suitable rotational position and pushed back into the housing 20 until it is retained by the locking arms 20LA as shown in FIG. 76. The optical fiber 92 is properly secured to the splint 30 and the end face of the splint 30 is polished.

[0181] Furthermore, the ferrule support 49 can be configured to fit the ferrule 30 relative to the housing 20. FIG. 77 is a detailed perspective view of the ferrule 30 arranged in the ferrule support 49. As shown, the ferrule support 49 comprises a plurality of recesses 49R formed in the flange 49F for QAOQnn / zznz / E / YiAi Tune the connector. In this configuration, the flange 49F has four cavities 49R that allow four different rotation positions for the ferrule / splint support 30 49, thus enabling quadrant adjustment. Figure 78 is a detailed front view of the connector 10 showing that the front opening of the housing 20 is sized to allow insertion of the ferrule supports. In addition, a portion of the conduit 22 is sized to cooperate with the flange 49F and allow different rotation positions. Consequently, after measuring the end face profile of the ferrule 30 or measuring the insertion loss, the ferrule 30 can be adjusted, if desired, to improve performance, as a Grade B standard.For clarification, the 20LA engagement arms can be deflected outwards to release the splint support 49, and then the splint support 49 is rotated to the desired position and reinserted into the housing 20 until it is retained by the 20LA engagement arms. Other versions of the splint support 49 may have other suitable numbers of rotation positions as desired.

[0182] The connector housing concepts described herein can also be used with multi-fiber connectors. By way of example, FIG. 79 is an assembled perspective view of a cable assembly 300 comprising a multi-fiber optic connector 200 that QAOQnn / zznz / E / YiAi has a housing 220. Housing 220 is similar to other housings 20 described herein, comprising a rear end (221) and a front end (223) with a longitudinal channel (222) extending from the rear end (221) to the front end (223). Housing 220 comprises a portion of the rear portion (RP) having a round cross-section (RCS) and a portion of the front portion (FP) having a non-round cross-section (NRCS). For further explanation, the front portion (FP) may have a rectangular cross-section with rounded sides (RS), providing a first orientation feature for the connector to align during mating and prevent insertion into an incompatible device or port, as best illustrated in Figure 93.

[0183] Housing 220 also comprises a transition region (TR) disposed between the rear portion (RP) and the front portion (FP) as best shown in Figs. 92 and 93. The transition region (TR) of housing 220 comprises a threaded portion TP like other housings 20 described herein. Housing 220 also comprises locking features 20L integrally formed in the housing 220 as best shown in Fig. 92. Fig. 80 represents the multifiber optical connector 200 which may use an attached dust cap 280 to protect a ferrule 230 from dust, debris, and the like when not connected. As with other configurations described in this document, the 280 dust cap can be configured to attach to the 220 housing using the threaded portion (TP).

[0184] Figure 81 represents an exploded view of cable assembly 300 having a multifiber connector 200. As shown, the connector 200 comprises a housing 220, a multifiber ferrule 230, a ferrule support 249, a ferrule support retainer 245, a spring member 250, a cable adapter 259, and a nozzle 260. The connector may include other components, such as one or more O-rings 65 that fit the housing 220. The connector 200 may have other components, arrangements, or configurations depending on various factors, such as the cable or other considerations. Cable 90 is similar to the other cables described herein, but has a plurality of optical fibers. Cable assemblies 300 may use any suitable cable design.

[0185] Figures 82-93 show the details and construction of cable assembly 300. Figures 82 and 83, respectively, are a detailed exploded and assembled view showing a pre-assembly of multifiber connector components 200 before the cable 90 passes through the pre-assembly. The pre-assembly comprises a ferrule support 249, a ferrule support retainer 245, a spring member 250, and a cable adapter 259. The retainer of the support 245 of The ferrule comprises an opening 245A sized to receive a portion of the ferrule support 249 through it when attached to the cable adapter 259 as shown in FIG. 83. The ferrule support retainer 245 also comprises one or more fastening features 245W for securing the ferrule support retainer 245 to a front portion of the cable adapter 259. The cable adapter 259 comprises a conduit 259P from the rear end to the front end for receiving the optical fibers 92. The opening at the front end of the cable adapter 259 is sized to receive the elastic member 250 and has a rear stop for seating the elastic member 250. When the splint bracket retainer 245 is attached to the cable adapter 259, the elastic member 250 pushes the splint bracket 249 forward into position.The 245W securing features of the splint bracket retainer 245 cooperate with the 259F securing features, such as the protrusions of the cable adapter 259, to secure the splint retainer 245. As depicted in FIG. 83, the front portions of the cable adapter 259 are exposed between the arms of the splint bracket retainer 245, and the front portion of the splint bracket 249, which has the recessed portion 249R, is exposed. The cable adapter 259 may also include a strain relief portion 259S to inhibit sharp bends. QAOQnn / zznz / E / γΐΛΐ cable near connector 200.

[0186] Figure 84 is a perspective view showing the cable 90 prepared for insertion into the pre-assembly of FIG. 83 with suitable lengths of resistor components 94 and exposed optical fibers 92. Figures 85 and 86 represent, respectively, a perspective view and a cross-sectional view of the cable 90 threaded through the pre-assembly of FIG. 83, such that the optical fibers 92 extend well beyond the ferrule support 249. As shown, the cable adapter 259 has holes on the opposite side so that the resistor components 94 extend through the holes and into the slots 259G of the cable adapter 259. Adhesive or other fastener can be applied to the resistor components 94 to secure them to the cable adapter 259. Figure 87 represents a detailed perspective view of the assembly of Fig.83 after a portion of the optical fiber coating 92 is removed in preparation for inserting the ends of the optical fibers 92 into the multifiber ferrule 230. Waiting to separate the coating from the optical fibers 92 to this point in the assembly provides protection to the optical fibers 92 until they are ready to be inserted into the multifiber ferrule 230.

[0187] Figs. 88 and 89 show the multifiber ferrule 230 attached to the optical fibers 92 and the rear end of the QAOQnn / zznz / E / YiAi is attached to housing 220. Like the other nozzles described here, nozzle 260 can be attached in a similar way. Such as adhesive, welding and / or mechanical means such as cooperative windows and projections.

[0189] Other variations of the 220 housings are possible based on the concepts described. As an example of another housing for use with the multifiber connector, the housing can be defined as comprising a back portion (RP) having a polygonal cross-section (PCS) and a front portion having a non-round cross-section (NRCS). The front portion (FP) or the back portion (RP) of this explanatory housing can be further defined in various configurations as described herein while retaining a back portion (RP) with the polygonal cross-section (PCS) and a front portion (FP) with a non-round cross-section (NRCS). By way of example, the polygonal cross-section (PCS) can be a hexagon, a rectangle, a square, or another suitable polygon, as desired.Similarly, the complementary device or port would be configured to properly fit the housing.

[0190] Other variations of the housing 20 for connectors 10 are possible. Figs. 94 and 94A represent a perspective view and cross-sectional views of another QAOQnn / zznz / E / γΐΛΐ connector housing that can be used with any of the suitable concepts described. In this embodiment, the rear portion RP is not round and has a polygonal cross-section PCS as shown by the cross-section in FIG. 94A. Figure 94A shows that this housing 20 can have 20K encoding features that can take any suitable shape or can have a 20KP encoding portion as desired. Similarly, this housing 20 can use any suitable 20L locking feature as desired.

[0191] Although the disclosure has been illustrated and described herein by reference to specific explanatory modalities and examples thereof, it shall be evident to those skilled in the art that other modalities and examples may perform similar functions and / or achieve similar results. All such equivalent modalities and examples are within the spirit and scope of the disclosure and are intended to be covered by the appended claims. It shall also be evident to those skilled in the art that various modifications and variations may be made to the disclosed concepts without departing from the spirit and scope thereof. Therefore, it is intended that this application shall cover such modifications and variations so long as they fall within the scope of the appended claims and their equivalents.

Claims

1. An optical fiber connector, comprising: a housing (20) comprising a rear end (21) and a front end (23) with a longitudinal conduit (22) extending from the rear end (21) to the front end (23), the housing (20) comprising a front portion (FP) and a rear portion (RP), wherein the rear portion (RP) of the housing (20) comprises a female encoder and at least one locking feature (20L) integrally formed in the rear portion (RP) of the housing (20), and the at least one locking feature (20L) is disposed about 180 degrees from the female encoder; and a ferrule (30) comprising at least one fiber hole (32).

2. The optical fiber connector of claim 1, wherein the housing (20) further comprises a transition region (TR) disposed between the front portion (FP) and the rear portion (RP) of the housing (20).

3. The optical fiber connector of claim 1 or 2, wherein an encoding portion (20KP) or the female encoder extends into the QAOQnn / zznz / E / YiAi (TR) transition region.

4. The optical fiber connector of claim 2 or 3, wherein the transition region (TR) comprises a threaded portion (TP).

5. The fiber optic connector of any one of claims 1 to 4, wherein a portion of the rear portion (RP) of the housing (20) comprises a round cross-section (RCS) and a portion of the front portion (FP) of the housing (20) comprises a non-round cross-section (NRCS).

6. The optical fiber connector of claim 5, wherein the threaded portion (TP) extends from the non-round cross section (NRCS) to the round cross section (RCS).

7. The optical fiber connector of any one of claims 1 to 6, wherein the front portion (FR) of the housing (20) comprises another portion of cross-section (ACSP). QAOQnn / zznz / E / γΐΛΐ 8. The optical fiber connector of any one of claims 1 to 7, wherein the at least one locking feature (20L) is a notch comprising a retaining surface formed in the housing (20). QAOQnn / zznz / E / γΐΛΐ 9. The fiber optic connector of any one of claims 1 to 8, wherein the at least one locking feature (20L) is a notch, groove, or scalloped edge formed in the housing (20).

10. The fiber optic connector of claim 8 or 9, wherein the at least one locking feature (20L) provides a predetermined retention force of 50 pounds or more.

11. The optical fiber connector of any one of claims 1 to 7, wherein the at least one locking feature (20L) is integrally formed in the housing (20) and comprises a ramp with a projection.

12. The fiber optic connector of any one of claims 1 to 11, further comprising a cable adapter (59).

13. The fiber optic connector of any one of claims 1 to 12, further comprising an O-ring (65).

14. The optical fiber connector of claim 13, wherein the O-ring (65) is disposed behind the at least one locking feature (20L).

15. The fiber optic connector of any one of claims 1 to 14, being a portion of a cable assembly (100).

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