Lensed ferrules for compact optical connectors

Abstract

The present disclosure includes a ferrule for a fiber optic connector and related connectors, methods, and assemblies. The ferrule may include a body defining an end face, a top side and a bottom side defining a height dimension of the body therebetween with a longitudinal axis of the ferrule defined perpendicular to the height dimension. The body may include an optical region defining at least one fiber-side light-permeable surface and at least one end-side light-permeable surface. The at least one end-side light-permeable surface may be defined along the end face. In some embodiments, the body may include at least one light-turn surface configured to reflect optical signals from the at least one fiber-side light-permeable surface towards the at least one end-side light-permeable surface at a nonzero angle relative to the longitudinal axis, and the optical region may be configured to at least partly focus the optical signals.

Description

LENSED FERRULES FOR COMPACT OPTICAL CONNECTORSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 635,666, titled “Expanded Beam Lensed Shoulder-less Ferrule”, filed April 18, 2024, which application is hereby incorporated by reference in its entirety.BACKGROUND

[0002] Fiber optic ferrules are utilized in the telecommunications industry as part of fiber optic connectors for connecting optical fibers to various telecommunications structures to convey optical signals. These connectors typically require substantial lateral space, limiting their suitability for applications where high connection density is desired. The alignment and mating processes for these ferrules with other ferrules or telecommunications structures may involve complex structures and procedures, which can lead to inconsistent connections and potential errors during installation as well as a need for significant rack and / or board space to make a single connection. External factors such as dust accumulation on exposed ferrule surfaces can negatively impact transmission efficiency. These limitations have presented ongoing challenges for fiber optic network deployments, particularly in scenarios demanding compact, reliable, and high- performance optical connections.SUMMARY

[0003] Through applied effort, ingenuity, and innovation, many of these identified deficiencies and problems have been solved by developing solutions that are structured in accordance with the embodiments of the present disclosure, many examples of which are described in detail herein.

[0004] Embodiments of the present disclosure include a ferrule for a fiber optic connector. The ferrule includes a body. The body may define an end face, a top side, a bottom side, a first side, a second side, and an optical region. The top side and the bottom side may define a height dimension of the body therebetween with a longitudinal axis of the ferrule defined perpendicular to the height dimension. The end face may be defined between the top side and the bottom side, and the top side and the bottom side may extend rearwardly from the end face. A first side surfacemay join the top side and the bottom side on the first side of the body, and a second side surface may join the top side and the bottom side on a second side of the body opposite the first side. The optical region may define at least one fiber-side light-permeable surface, at least one lens surface, and at least one end-side light-permeable surface. The at least one end-side light-permeable surface may be defined along the end face. The at least one lens surface may be configured to reflect optical signals from the at least one fiber-side light-permeable surface towards the at least one endside light-permeable surface at a nonzero angle relative to the longitudinal axis.

[0005] In some embodiments, the at least one light-turn surface defines at least one lens surface, wherein the optical region is configured to at least partly focus the optical signals via the at least one lens surface. In some embodiments, the at least one end-side light-permeable surface defines at least one lens surface, wherein the optical region is configured to at least partly focus the optical signals via the at least one lens surface.

[0006] The body may have a maximum height dimension of 1.85 mm between the top side and the bottom side and / or a maximum width dimension of 6.4 mm between the first side and the second side. The at least one end-side light-permeable surface may extend farther forward relative to the longitudinal axis than at least the bottom side of the body. The body may further include at least one pin opening defining a pin axis along which a pin is configured to extend from the body, and the pin axis may be parallel to the longitudinal axis.

[0007] In some embodiments, the longitudinal axis and at least a portion of the end face form an oblique angle. For example, the longitudinal axis and a mating surface of the end face may form the oblique angle. The at least one end-side light-permeable surface may define a normal vector oriented parallel to a plane of the mating surface. In some embodiments, the mating surface may be planar and reversible, such that the mating surface of the ferrule is configured to abut a second mating surface of a second ferrule having opposing oblique angles, and the mating surface may be configured to form a circumferential seal with the second mating surface to prevent the optical signals from escaping. The mating surface may be opaque.

[0008] In some embodiments, the at least one light-turn surface may be totally internally reflective of the optical signals received from the at least one fiber-side light-permeable surface. The at least one end-side light-permeable surface may define a normal vector oriented towards the body, such that the ferrule is passively eye safe. In some embodiments, the optical signals leaving the at least one end-side light-permeable surface do not propagate outside a footprint of the body.The at least one end-side light-permeable surface may define a normal vector oriented sixty to eighty degrees relative to the longitudinal axis.

[0009] In some embodiments, at least a portion of the at least one end-side light-permeable surface may be disposed below a horizontal center plane of the body, the horizontal center plane being parallel to the longitudinal axis and perpendicular to the height dimension. The at least one end-side light-permeable surface may face at least partially towards the horizontal center plane of the body.

[0010] In some embodiments, the ferrule may comprise a first pin or first pin opening defined at the end face, and a second pin or second pin opening defined at the end face on an opposite side of the at least one end-side light-permeable surface from the first pin or the first pin opening. At least a portion of the at least one end-side light-permeable surface may face towards a width axis extending between (a) the first pin or the first pin opening and (b) the second pin or the second pin opening. The optical region may comprise three or more light-turn surfaces including the at least one light-turn surface configured to reflect the optical signals from three or more corresponding optical fibers. The three or more light-turn surfaces may be internally concave within the optical region, and the three or more light-turn surfaces may be shaped to collimate the optical signals prior to exiting the at least one end-side light-permeable surface. The ferrule may include a top surface defining a top cutout and a bottom surface defining a bottom cutout.

[0011] In some embodiments, the nonzero angle may define an oblique angle relative to the longitudinal axis. The oblique angle may be less than ninety degrees relative to the longitudinal axis. In some embodiments, the nonzero angle may be parallel to a portion of the end face adjacent the at least one end-side light-permeable surface and perpendicular to the at least one end-side light-permeable surface. The at least one fiber-side light-permeable surface may define an oblique angle relative to the height dimension of the body such that the at least one fiber-side light- permeable surface is oblique from the optical signals prior to entering the at least one fiber-side light-permeable surface. In some embodiments, the body may include a unitary molded structure. In some embodiments, the body may include a plurality of pieces.

[0012] In some embodiments, the body further defines at least one opening configured to receive at least two optical fibers therethrough. The optical region may be transparent. The at least one end-side light-permeable surface may be defined at a height position within the heightdimension of the body. The first side surface and the second side surface may each be smooth. In some embodiments, the ferrule is shoulderless.

[0013] Some embodiments of the present disclosure include a connector. The connector may include a connector housing defining a housing opening at a front end of the connector housing. The connector may further include a ferrule in accordance with any of the various embodiments discussed herein. In some embodiments, the connector housing may be configured to overhang the end face of the body of the ferrule relative to the longitudinal axis. The nonzero angle may be defined such that the optical signals are configured to interact with the connector housing.

[0014] Various embodiments of the present disclosure may include a connection system. The connection system may include two or more connectors in accordance with any of the various embodiments discussed herein. The connection system may include a receptacle comprising a receptacle opening extending from a first end to a second end of the receptacle. A first connector may be configured to insert into the receptacle opening from the end and a second connector being configured to insert into the receptacle opening from the second end. The ferrule of the first connector and the ferrule of the second connector may define an exchange zone therebetween through which the optical signals are configured to pass between the ferrule of the first connector and the ferrule of the second connector.

[0015] In some embodiments, the receptacle may be configured to receive a plurality of connectors including the first connector, the second connector, and a third connector. The first connector and the third connector may be configured to engage the receptacle parallel to each other and be disposed less than the height dimension away from each other when engaged with the receptacle.

[0016] Some embodiments may include a method of molding a ferrule. The method may include injecting at least one polymer into a mold. The mold may include a plurality of surfaces configured to cause the at least one polymer to form a ferrule in accordance with any of the various embodiments discussed herein.

[0017] In some embodiments, a ferrule may be provided that includes a body defining at least one row of lens surfaces. For example, in some embodiments, a ferrule may include a plurality of rows of lens surfaces and a plurality of rows of fiber-side light permeable surfaces. In some embodiments, a first length of the optical region of the body along the longitudinal axis between a first lens surface of a first row of lens surfaces of the plurality of rows of lens surfaces and a firstfiber-side light-permeable surface of a first row of the plurality of rows of fiber-side light- permeable surfaces of the body may be greater than a second length of the optical region of the body along the longitudinal axis between a second lens surface of a second row of lens surfaces of the plurality of rows of lens surfaces and a second fiber-side light-permeable surface of a second row of the plurality of rows of fiber-side light-permeable surfaces of the body.

[0018] Some embodiments may include a bag of parts comprising one or more components described in various embodiments herein. For example, a bag of parts may include a connector housing and a ferrule in accordance with any of the various embodiments discussed herein.

[0019] BRIEF DESCRIPTION OF FIGURES

[0020] Having thus described certain example embodiments of the present disclosure in general terms above, non-limiting and non-exhaustive embodiments of the subject disclosure are described with reference to the following figures, which are not necessarily drawn to scale and wherein like reference numerals refer to like parts throughout the various views unless otherwise specified. The features illustrated in the figures may or may not be present in certain embodiments described herein. Some embodiments may include fewer (or more) features than those shown in the figures. As discussed herein, various portions of the embodiments shown in the figures may be interchanged for or used with portions of other embodiments shown in the figures without departing from the scope of the present disclosure.

[0021] FIG. l is a front perspective view of an embodiment of a lensed ferrule, in accordance with an example embodiment of the present disclosure.

[0022] FIG. 2 is a front view of the lensed ferrule of FIG. 1, in accordance with an example embodiment of the present disclosure.

[0023] FIG. 3 is a bottom view of the lensed ferrule of FIG. 1, in accordance with an example embodiment of the present disclosure.

[0024] FIG. 4 is a rear view of the lensed ferrule of FIG. 1, in accordance with an example embodiment of the present disclosure.

[0025] FIG. 5 is a partial side sectional view of the lensed ferrule of FIG. 1, in accordance with an example embodiment of the present disclosure.

[0026] FIG. 6 is a full side sectional view of the lensed ferrule of FIG. 1, in accordance with an example embodiment of the present disclosure.

[0027] FIG. 7 is a front perspective view of a multi-row lensed ferrule, in accordance with an example embodiment of the present disclosure.

[0028] FIG. 8 is a front view of the multi -row lensed ferrule of FIG. 7, in accordance with an example embodiment of the present disclosure.

[0029] FIG. 9 is a bottom view of the multi-row lensed ferrule of FIG. 7, in accordance with an example embodiment of the present disclosure.

[0030] FIG. 10 is a rear perspective view of the multi-row lensed ferrule of FIG. 7, in accordance with an example embodiment of the present disclosure.

[0031] FIG. 11 is a partial side sectional view of the multi-row lensed ferrule of FIG. 7, in accordance with an example embodiment of the present disclosure.

[0032] FIG. 12 is a full side sectional view of the multi-row lensed ferrule of FIG. 7, in accordance with an example embodiment of the present disclosure.

[0033] FIG. 13 is a perspective view of a light turn lensed ferrule, in accordance with an example embodiment of the present disclosure.

[0034] FIG. 14 is a front view of the light turn lensed ferrule of FIG. 13, in accordance with an example embodiment of the present disclosure.

[0035] FIG. 15 is a bottom view of the light turn lensed ferrule of FIG. 13, in accordance with an example embodiment of the present disclosure.

[0036] FIG. 16 is a rear perspective view of the light turn lensed ferrule of FIG. 13, in accordance with an example embodiment of the present disclosure.

[0037] FIG. 17 is a partial side sectional view of the light turn lensed ferrule of FIG. 13, in accordance with an example embodiment of the present disclosure.

[0038] FIG. 18 is a full side sectional view of the light turn lensed ferrule of FIG. 13, in accordance with an example embodiment of the present disclosure.

[0039] FIG. 19 is a front perspective view of another light turn lensed ferrule, in accordance with an example embodiment of the present disclosure.

[0040] FIG. 20 is a partial side sectional view of the light turn lensed ferrule of FIG. 19, in accordance with an example embodiment of the present disclosure.

[0041] FIG. 21 is a perspective view of yet another light turn lensed ferrule, in accordance with an example embodiment of the present disclosure.

[0042] FIG. 22 is a partial side sectional view of two light turn lensed ferrules engaged with each other, in accordance with an example embodiment of the present disclosure.

[0043] FIG. 23 is a perspective view of a connector, in accordance with an example embodiment of the present disclosure.

[0044] FIG. 24 is a flowchart illustrating an example method of manufacturing a connector, in accordance with an example embodiment of the present disclosure.DETAILED DESCRIPTION

[0045] One or more embodiments are now more fully described with reference to the accompanying drawings, wherein like reference numerals are used to refer to like elements throughout and in which some, but not all embodiments of the inventions are shown. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the various embodiments. It is evident, however, that the various embodiments may be practiced without these specific details. It should be understood that some, but not all embodiments are shown and described herein. Indeed, the embodiments may be embodied in many different forms, and accordingly this disclosure should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements.

[0046] As used herein, the term “exemplary” means serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Rather, use of the word exemplary is intended to present concepts in a concrete fashion. In addition, while a particular feature may be disclosed with respect to only one of several embodiments, such feature may be combined with one or more other features of the other embodiments as may be desired and advantageous for any given or particular application. Furthermore, to the extent that the terms “includes” and “including”, and variants thereof are used in either the detailed description or the claims, these terms are intended to be inclusive in a manner similar to the term “comprising.”

[0047] As used herein, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or”. That is, unless specified otherwise, or clear from context, “X employs A or B” is intended to mean any of the natural inclusive permutations. That is, if X employs A; X employs B; or X employs both A and B, then “X employs A or B” is satisfied under any of the foregoing instances. In addition, the articles “a” and “an”, as well as any subsequent use of “the” in reference to the same term, as used in this application and the appended claims should generally be construed to mean “one or more” unless specified otherwise or clear from context to be directed to a singular form.

[0048] As used herein, the terms “coupled,” “fixed,” “attached to,” and the like refer to both direct coupling, fixing, or attaching, as well as indirect coupling, fixing, or attaching through one or more intermediate components or features, unless otherwise specified herein.

[0049] As used herein, the term “at least partially” refers to partially or fully. As used herein, terms of approximation, such as “approximately,” “substantially,” or “about,” refer to being within manufacturing or engineering tolerances. For example, terms of approximation may refer to being within a five percent margin of error. Such terms are also inclusive of the exact value indicated.

[0050] As used herein, terms of direction such as “top”, “upper”, “lower”, “bottom”, “front”, “rear” and the like are to be interpreted in the relative sense (e.g., relative to other components described with terms of direction) rather than in the absolute sense. For example, an “upper” side of an object may instead be the lowest part of the object if flipped upside down. “Front” or “forward” generally refers to a region or end portion that mates with another optical component. Likewise, “rear” or “back” or “backward” is generally the direction opposite the front, which in some embodiments includes the direction from which optical fibers enter a component, e.g., a ferrule or a fiber optic connector.

[0051] Various fiber optic connectors (also referred to as “connectors”) may be used with various embodiments of ferrules disclosed herein to efficiently transport optical signals to and from optical connections in various receptacles of various receiving telecommunications structures including, but not-limited to, (a) one or more adapters in adapter panels for joining multiple lengths of optical fiber (e.g., cables carrying optical signal via fiber), such as the receptacles described herein, (b) transceivers and related receptacles configured to receiveand convert the optical signal into electrical signals; (c) or any other receptacle structure couplable to a fiber optic connector.

[0052] Embodiments discussed herein may include various fiber optic connectors including small form factor connectors comprising supporting one or more of the depicted ferrules. Some small form factor connectors may be used for high density applications (e.g., in hyper-scale data centers). Examples of such connectors include the MDC and the MMC brand connectors provided by U.S. Conec Ltd. These connectors may meet the very small form factor (“VSFF”) footprint requirements per industry multi-source agreements such as QSFP-DD and SFP-DD and the functionality of such connectors may meet various testing standards. Generally, as described herein, various embodiments are used with such VSFF footprint connectors such that the connector housing has a height that is greater than a width of the housing. Moreover, the depicted ferrules may be configured to fit a miniature multifiber ferule footprint, such as the footprint of the TMT ferrule sold by U.S. Conec Ltd., which ferrules may be significantly smaller than shouldered MT ferrules also sold by U.S. Conec Ltd.

[0053] Embodiments of the present disclosure may utilize connectors with lensed ferrules. For example, the lensed ferrules may be used with MXC® brand connectors or PMT® brand connectors provided by the Applicant. A lensed ferrule may be used in fiber optic connectors to facilitate optical signal transmission. For example, a lensed ferrule may be a multi-fiber ferrule configured to terminate a plurality of optical fibers to transmit and / or receive optical signals between the optical fibers. The lensed ferrule may engage or mate with an exterior of another ferrule (e.g., for communicating optical signals between the lensed ferrule and the another ferrule or other telecommunications structure). In some embodiments, a lensed ferrule may comprise a single-row configuration, a multi-row configuration, or a light turn configuration in accordance with the various embodiments disclosed herein. Moreover, in some embodiments, one or more of the ferrules disclosed herein may be a small form factor “shoulderless” ferrule, which may include one or more structural features, such as a cutout (also referred to interchangeably as a notch, recess, depression, indentation, concavity, or the like without regard to its underlying manufacturing process), for engaging a connector housing, without a corresponding protruding flange or other outwardly projecting engagement surface. Each configuration may provide specific technical advantages.

[0054] A lensed ferrule, such as a single-row lensed ferrule, multi-row lensed ferrule, and / or light turn lensed ferrule may allow for efficient coupling of optical signals in a compact form factor. The ferrules may include a plurality of lens surfaces that each at least partially augment optical signals transmitted into the ferrule from an optical fiber, transceiver, or other optical signal transmitting component (e.g., as used with various telecommunications structures). The body of the ferrule may be structured to promote ease of manufacturing, ease of assembly, signal transmission quality, and reduced crosstalk between adjacent optical fibers. In some embodiments, the lens surfaces of a lensed ferrule may collimate optical signals, which may enhance signal robustness in view of dust and debris, and reduce transmission losses. This collimation effect may be present in single-row, multi-row, and light turn configurations. The various embodiments of ferrule herein may be reversible and hermaphroditic, such that a ferrule may be capable of engaging duplicates of itself.

[0055] A single-row lensed ferrule may be used in at least some applications and may include a plurality of independent signal paths formed by the body therethrough. The single-row lensed ferrule may arrange these signal paths side-by-side in a “row” structure with the lens surfaces and related body structures being arranged in side-by-side along a single row.

[0056] A multi-row lensed ferrule may enable higher density connections by accommodating multiple rows of optical fibers within a single ferrule body. In some embodiments, a multi-row lensed ferrule may have the same maximum external dimensions (e g., length, width, height) as a single-row or light turn lensed ferrule. In some embodiments, the multi-row lensed ferrule may include a plurality of rows spaced in a first direction (e.g., along a height dimension of the ferrule) with each row having a plurality of lens surfaces and corresponding optical pathways along a second direction (e.g., along a widthwise dimension of the ferrule).

[0057] A light turn lensed ferrule may redirect optical signals at a nonzero angle relative to a longitudinal axis of the ferrule. In some instances, the longitudinal axis may correspond to an axis along which the optical signals are transported by an optical fiber terminated inside the light turn lensed ferrule. The light turn lensed ferrule may provide unique benefits compared to other ferrules, including non-light-turn ferrules. In some embodiments, the light turn configuration may allow for axial engagement of multiple ferrules via positioning the light turn components (e.g., an end face light permeable surface) at an end face of the ferrule body. This axial engagement capability may enable narrower rows of adjacent connectors to be implemented, potentiallyincreasing connection density as compared to other ferrules requiring lateral (e.g., in a height or width direction of the ferrule) motion to engage. For example, ferrule to ferrule coupling between two light turn lensed ferrules (e.g., ferrules 300, 400, 500 shown in FIGS. 13-22) may occur at the “front” of this ferrule (e.g., end face to end face), and thus, the ferrules do not need to overlap axially for vertical coupling (e.g., one ferrule on top of the other) beyond the overlap in the end face exchange region between the two end faces. Such embodiments may require less space for connections and may be useful in high density applications. Additionally, the light turn design may facilitate improved optical connections by allowing for more precise alignment between mating ferrules, such as by simplifying the engagement and limiting the degrees of freedom of the connector and ferrule during coupling and / or use.

[0058] A connection system may comprise a first connector and a second connector, each incorporating a lensed ferrule. Rather than a second connector, for example, some embodiments, including but not limited to a light turn lensed ferrule, may be configured to directly engage a telecommunications structure such as a circuit board, transceiver, or the like. In some embodiments, a first connector may be configured to engage a second connector using a coupling device, such as a receptacle or an adapter. In some embodiments, the lensed ferrules of the first and second connectors may define an exchange zone through which optical signals may pass between the ferrules. This exchange zone may enable efficient optical coupling between the connectors while maintaining signal integrity. In some embodiments, the exchange zone may be optically isolated from an external environment by engaging corresponding mating surfaces between ferrules. It will be appreciated by one of ordinary skill in the art after reading this disclosure that the same ferrule may receive or transmit, or both, and optical beams therein may travel bi-directionally. Thus, any reference herein to one direction applies equally in the opposite direction of travel of the optical beams. For example, focusing of an optical beam in one direction is equivalent to divergence of the optical beam in the opposite direction, and the like.

[0059] In some embodiments, a lens surface of a lensed ferrule may be configured to reflect optical signals from a fiber-side light-permeable surface towards an end-side light-permeable surface at a nonzero angle relative to the longitudinal axis of the ferrule (e.g., when transmitting optical signals). When receiving optical signals, the lens surface may be configured to reflect optical signals from an end-side light-permeable surface received at a nonzero angle relative to the longitudinal axis of the ferrule towards a fiber-side light-permeable surface along the longitudinalaxis. This reflection at or from a nonzero angle may allow for more compact ferrule designs and may facilitate the light turn configurations disclosed herein.

[0060] The lensed ferrule may, in some embodiments, be structured to ensure that optical signals leaving the end-side light-permeable surface do not propagate outside the footprint of the ferrule body. This containment of optical signals within the ferrule body's footprint may enhance signal security and reduce potential interference with adjacent optical pathways. For example, in some embodiments, the lensed ferrule may turn optical signals towards at least a portion of the body of the ferrule such that optical signals cannot reach the user's eye even when no corresponding receiving ferrule or other telecommunications structure is connected (e.g., passively eye safe when unmated).

[0061] In some embodiments, a lensed ferrule may be designed to be shoulderless. A shoulderless configuration may allow for greater flexibility in ferrule placement, may allow a reduced footprint and greater density of connectors, and may simplify the manufacturing process for this smaller footprint ferrule. The shoulderless design provides a smaller form factor by eliminating protruding structures such as shoulders, flanges, or similar elements that may extend outward from the ferrule body. Instead, the shoulderless lensed ferrule incorporates alternative engagement features such as cutouts that enable secure connection with a connector housing while maintaining a compact profile. This design approach reduces the overall lateral footprint of the ferrule, allowing for higher density installations in space-constrained environments. The absence of shoulders also facilitates easier insertion and extraction of the ferrule within connector assemblies, potentially improving field installation efficiency and reducing the risk of damage during handling. In addition, adding shoulders to the smaller footprint lensed ferrule may be less reliable as such smaller shoulders may be prone to breakage if used as a seating-unseating surface for the ferrule inside the connector housing. An example shouldered, lensed ferrule is shown and described in U.S. Patent No. 9,563,027, filed October 19, 2010, and entitled “Unitary multi-fiber optical ferrule with integrated lenses”, which is incorporated by reference herein in its entirety.

[0062] Referring to FIGS. 1-6, an example embodiment of a lensed ferrule 100 is illustrated. The various features of the various depicted embodiments may be usable with each other and may be interchangeable, in whole or in part. Unless described or depicted otherwise, features disclosed respect to one embodiment may apply to the remaining embodiments. In the depicted embodiment, the lensed ferrule 100 includes a body 102 defining various structural features. The body 102 maydefine an end face 104, a top side 106, a bottom side 108, with a first side 1 14 and a second side 118 extending between the top side and bottom side on opposite lateral sides of the body. A height dimension 110 of the body 102 may be defined between the top side 106 and the bottom side 108. A longitudinal axis 112 of the lensed ferrule 100 may be defined perpendicular to the height dimension 110. In operation, the lensed ferrule 100 may be positioned into engagement with another ferrule or other telecommunications structure along the longitudinal axis 112. The body 102 may further include a first side surface 116 joining the top side 106 and the bottom side 108 on the first side 114 of the body 102. Similarly, a second side surface 120 may join the top side 106 and the bottom side 108 on the second side 118 of the body 102 opposite the first side 114. In some embodiments, the body 102 may have a maximum height dimension 110 of 1.85 mm. The body 102 may have a maximum width dimension of 6.4 mm between a first side 114 and a second side 118. The body may have a maximum length dimension of 4mm. In some embodiments, the body 102 may be larger or smaller than the indicated dimensions. In some embodiments, the body 102 may be within 5% of 1.85mm tall (e.g., 1.7575mm to 1.9425mm); within 5% of 6.4mm wide (e.g., 6.08mm to 6.72mm); and / or within 5% of 4mm long (e.g., 3.8mm to 4.2mm). Example miniature multi-fiber ferrules that are made of opaque material (and hence, cannot be lensed) are shown and described in U.S. Patent No. 12,019,278, filed April 23, 2021, and entitled “Miniature multi-fiber ferrule”, which is incorporated by reference herein in its entirety.

[0063] The body 102 of the lensed ferrule may be constructed from a variety of materials that can be molded and possess at least partial transparency for allowing optical signals to propagate through the optical region(s) (e.g., optical regions 122 described with respect to FIGS. 5-6). In some embodiments, the body 102 may be made from one or more polymers. These polymers may include thermoplastics such as polycarbonate, acrylic (e.g., polymethyl methacrylate or PMMA), polystyrene, cyclic olefin polymer (COP), cyclic olefin copolymer (COC), polysulfone (PSU), or polyether (PEI). For example, at least the optical region of the polymer may be made of an optically transparent or near transparent polymer. In some embodiments, the body 102 may be formed from thermosetting plastics like epoxy resins or polyurethanes. The body 102 may also be made from composite materials that combine different polymers or incorporate additives to enhance specific properties. For example, the body may be formed from a blend of polycarbonate and polyester to balance optical and mechanical characteristics. In certain embodiments, the body may be constructed using multi-material molding techniques, allowing different regions of the ferrule tobe made from distinct materials with complementary properties. This approach may enable optimization of optical, mechanical, and thermal characteristics across different portions of the ferrule body.

[0064] While depicted as a single, unitary molded material, in some embodiments, the body 102 may be formed of multiple components (e.g., separately molded or otherwise formed components) attached to each other, whether permanently, semi-permanently, or temporarily. In such embodiments, the various components of the body may be the same material and / or one or more different materials.

[0065] In some embodiments, the side surfaces, top surface, and bottom surface of the body 102 may not necessarily be connected at perpendicular angles. Instead, as shown in FIGS. 1-6, the body 102 may incorporate various transitional features between these surfaces to enhance the ferrule's functionality, manufacturability, or aesthetic appeal. For example, as illustrated in FIG. 1, the body 102 may include chamfered corners 178 and rounded comers 180 at the intersections of different surfaces. In some embodiments, the chamfered comers 178 and / or the rounded corners 180 may be optional (e.g., 90 degree corners) and / or may be replaced with other shaped comers, including rounded or chamfered corners. Moreover, in some embodiments, at least a portion of the top surface 146 and bottom surface 148 may be parallel (e.g., the outermost planar portions of the top and bottom surfaces). In other embodiments, the top surface 146 and the bottom surface 148 need not be parallel. Similarly, in some embodiments, at least a portion of the first side surface 116 and the second side surface 120 may be, but are not required to be, parallel.

[0066] The chamfered corners 178 may provide a beveled or angled transition between adjacent surfaces, which may help reduce sharp edges and potential stress concentrations in the fermle structure. These chamfered transitions may also facilitate easier insertion of the ferrule into a connector housing or mating component. Similarly, the rounded corners 180 may offer a smooth, curved transition between surfaces. This rounded profile may further contribute to stress reduction, improve the ferrule's durability, and potentially enhance its optical performance by minimizing light scattering at surface intersections. The incorporation of these transitional features may vary depending on the specific requirements of the ferrule design. In some embodiments, chamfered corners 178 may be used at certain intersections while rounded corners 180 are employed at others. The extent and angle of chamfering or the radius of rounding may also be adjusted to suit particular design needs or manufacturing processes. These transitional features may extend along the entirelength of the ferrule body 102 or may be localized to specific regions, such as near the end face 104 or at the rear of the ferrule. In the depicted embodiment, having varied corner profiles (e.g., chamfered corners 178 on the bottom side transition and rounded corners 180 on the top side transition) may allow the ferrule to be keyed such that it may only engage a connector housing and / or receiving component (e.g., another ferrule, another connector, or another telecommunications structure) in a single orientation.

[0067] In some embodiments, the body 102 may include a top surface 146 defining a top cutout 150 and a bottom surface 148 defining a bottom cutout 152. The top cutout 150 and the bottom cutout 152 may be of different sizes to allow for the body 102 to be inserted into a connector housing in only one orientation (i.e., mechanical polarity). The top cutout 150 and bottom cutout 152 may be used to secure the ferrule within a connector housing. For example, these cutouts may engage with corresponding protrusions or other features within the connector housing, providing a mechanism for retention and alignment. This engagement may help stabilize the ferrule, particularly in a shoulderless design where traditional flanges or shoulders are absent. The illustrated ferrule 100 is shoulderless as it lacks any type of flange or protrusion extending from the top, bottom, or sides in the rear portion of the body. For example, the maximum width and maximum height of the ferrule 100 at the forwardmost and rearmost positions along the longitudinal axis 112 may be equal. The ferrule body 102 as illustrated maintains a consistent profile along its length, without the typical outward extensions or shoulders found in conventional ferrule designs, e.g., the PMT® ferrule provided by the Applicant. In some embodiments, intentional recesses are formed in the surfaces, such as the cutouts 150, 152 without necessarily including a protruding shoulder. Respective forward facing surfaces of these cutouts 150, 152 are where the ferrule 100 seats or engages features of the connector housing for secure seating and mating. A shoulderless design may offer several benefits. It may allow for a more compact form factor, potentially enabling higher density connections in space-constrained environments. The absence of shoulders may simplify the manufacturing process and reduce material usage. Additionally, a shoulderless design may facilitate easier insertion and extraction of the ferrule within connector assemblies, which may improve installation efficiency and reduce the risk of damage during handling given the small size of the body 102 (and hence smaller sized shoulders if those were to be implemented into the body 102).

[0068] With continued reference to FIGS. 1-6, the body 102 may further include at least one pin opening 132 defining a pin axis 134 along which a pin may be configured to extend from the body 102 and / or be inserted into the body. In the depicted embodiment, the lensed ferrule 100 includes two pin openings 132 (e.g., a first pin opening 132 defined at the end face 104 adjacent the first side 114 and a second pin opening 132 defined at the end face 104 on an opposite side of one or more end-side light-permeable surface(s) 128 from the first pin opening 132 adjacent the second side 118). Pins (e.g., metal or polymer cylinders) may be inserted into the pin openings 132 to create a directional ferrule (e.g., two pins engaged with a single ferrule may cause the ferrule to only engage pin-less receiving ferrules) or hermaphroditic ferrule (e.g., one pin engaged with a ferrule may allow the ferrule to engage other one-pin ferrules via inserting the pins into the opposing, pin-less pin openings of the counterpart ferrule). Alternatively, for a hermaphroditic configuration, the ferrule 100 may have a pin-like projection integrally molded and protruded from the end face 104, and have only one pin opening 132 to correspondingly receive a pin-like protrusion from another identical hermaphroditic ferrule. In some embodiments, the pin axis 134 may be parallel to the longitudinal axis 112.

[0069] In the depicted embodiment, the end face 104 of the body 102 may include a mating surface 138 having several recesses or other features formed therein. The recesses 174, 176 may facilitate various structural and optical interactions for the ferrule. For example, the end face 104 of the body 102 may also include a lens recess 174 in which one or more optical components for optical signal transmission are disposed as described herein. The end face 104 may, in some embodiments, define a pin recess 176 at each of the pin openings 132. The pin recesses 176 and lens recess 174 may be configured to prevent portions of a pin, portions of the body, or other structures from preventing the mating surface 138 from sealing against a corresponding mating surface 138 of another ferrule or other telecommunications structure. To form a seal, the mating surfaces 138 may but need not have identical shapes or symmetrical shapes, and in some embodiments, only a single sealing portion may need to align circumferentially around the area to be sealed (e.g., a seal around the lens recess 174 may be formed when at least some portion of the mating surfaces 138 engage around the recess).

[0070] In some embodiments, the lens recess 174 may comprise one or more end-side light- permeable surfaces 128 that form lens surfaces 126 along the width of the ferrule body 102 to facilitate receipt or emission of optical signals as described herein. The end-side light permeablesurfaces 128 may refer to the surface of the ferrule 100 that defines and comprises the lens surfaces 126, with the lens surfaces being a part of the one or more end-side light permeable surfaces. While depicted as discrete, concave (relative to the interior optical region 122 of the body 102) shapes forming each lens surface 126, the end-side light-permeable surfaces 128 may be formed into one or more other shapes to accomplish a lens function of the ferrule. In various other embodiments disclosed herein (e.g., the light turn lensed ferrules 300, 400, 500 of FIGS. 13-22), the ferrules may include separate end-side light-permeable surfaces and lens surfaces. For example, various embodiments may interchangeably use multiple or separate lens elements. For example, other lenses may be molded or otherwise formed in or attached to the body in addition to or instead of the lens surfaces 126 defined by the end-side light-permeable surfaces 128 while having the various optical features discussed herein.

[0071] In some embodiments, the number of lens surfaces 126 formed by the one or more end-side light-permeable surfaces 128 may correspond to the number of optical fibers that the ferrule is designed to interface with (e.g., sixteen in the depicted embodiment). In some embodiments, non-limiting examples of the number of lens surfaces include twelve, sixteen, twenty four (e.g., two by twelve), or thirty two (e.g., two by sixteen). A number of lens surfaces 126, and hence a number of optical fibers supported by the ferrule 100, is not arbitrary and is governed by system needs, fiber size (outer diameter) and manufacturing limitations. For example, a ferrule configured to accommodate multiple optical fibers may include a corresponding number of lens surfaces 126 to facilitate the transmission of optical signals from each fiber. FIGS. 7-12, discussed below, disclose an additional embodiment in which multiple rows of lens surfaces 126 formed by one or more sets of end-side light-permeable surfaces 128 are used to interface with multiple rows of optical signals from multiple rows of optical fibers. Referring back to FIGS. 1-6, in various embodiments, the lens structure, quantity, or configuration may be varied depending on the specific application and design requirements of the ferrule 100. For example, in some embodiments, single or dual lens surfaces may be used in respective single or dual fiber ferrule configurations. In some embodiments, at least two or more lens surfaces may be used to receive optical signals from and / or direct optical signals to at least two or more optical fibers. In some embodiments, three or more lens surfaces may be used in a three or more fiber ferrule configuration.

[0072] In some embodiments, two identical ferrules 100 with the same geometry may be engaged to form a connection therebetween. During engagement, the ferrules 100 may be positioned facing each other with the respective end faces 104 oriented towards each other with the pin axes 134 coaxially aligned such that two pins may connect the two ferrules by engaging the respective pin openings 132. The coupled ferrules 100 may be inverted relative to each other (e.g., rotated one hundred eighty degrees about the longitudinal axis 112 such that the top sides 106 of the respective ferrules are facing in opposite directions). The respective mating surfaces 138 of the ferrules 100 may contact each other to form a fully or partly light sealed exchange zone between the lens recesses 174 of the ferrules.

[0073] Turning to FIG. 3, in some embodiments, the body 102 may include a window 166 that connects to one or more fiber channels (e.g., open sided channels and / or enclosed conduits) through which the optical fibers may extend into the ferrule. The one or more fiber channels may also be referred to as optical fiber support structures. The window 166 may serve multiple functions in the ferrule design, including providing space for epoxy, access to the optical fibers and facilitating their secure fixation within the ferrule body 102. In some embodiments, the window 166 may extend along a portion of the body 102 (e.g., within the bottom cutout 152 in the depicted embodiment). This open structure may enable easier manipulation and alignment of the fibers during assembly.

[0074] The window 166 may connect to one or more fiber channels 168 (see, e.g., FIG. 6), which may guide the optical fibers towards a respective terminal fiber channel 170. The window 166 and / or open portions of the fiber channels may allow for the application of epoxy or other adhesive materials along the fiber path to rigidly secure the optical fibers within the ferrule 100. A gap between the terminal fiber channels 170 and remaining fiber channels 168 (also illustrated in FIG. 18) may be configured to receive a greater volume of the epoxy or other adhesive for better affixation in some instances. When epoxy or another adhesive is introduced into the window 166, it may flow into the connected fiber channels and around and between the optical fibers. This may create a strong bond between the fibers and the ferrule body 102, helping to maintain precise fiber alignment and prevent movement or displacement of the fibers over time. The open nature of the window 166 may allow for controlled application of the adhesive, ensuring thorough coverage and minimizing the risk of air bubbles or voids in the epoxy. The window 166 may also facilitate preassembly and post-assembly inspection and quality control processes. The open structure mayallow for visual confirmation of proper fiber placement and adhesive distribution, potentially improving manufacturing reliability and consistency.

[0075] In some embodiments, the terminal fiber channels 170 may be designed to precisely position the end of each optical fiber relative to the fiber-side light-permeable surface 124 of the body 102. See, e g., FIGS. 5, 6. In the depicted embodiment, the terminal fiber channels 170 each include a protrusion 172 extending at least partly circumferentially around the interior surface of the channels. The protrusions 172 may define a narrower cross-sectional area that serves to further secure and reliably position the ends of the optical fibers within the terminal fiber channels 170. For example, the protrusions 172 in the depicted embodiment form a u-shaped portion of the terminal fiber channels 170 that has a narrower cross-sectional area than the rest of the terminal fiber channels. The protrusions 172 may be at least partially spaced from the fiber-side light- permeable surface(s) 124 of the body 102 to avoid contacting the farthest distal ends of the optical fibers. For example, in some instances, forming the ends or tips of the optical fibers may cause distortions to the shapes of the fibers, such as mushrooming or bulging at the ends. Spacing the protrusions 172 from the fiber-side light-permeable surface(s) 124 of the body 102 may avoid contact between these deformed portions of the optical fibers and the protrusions. In some embodiments, as discussed herein, the optical fibers may be positioned with a gap between the distal ends of the optical fibers and the fiber-side light-permeable surface(s) 124.

[0076] Referring to FIG. 4, the body 102 may further define at least one opening 160 at a rear side thereof opposite the end face, and the pin openings 132 may, but are not required to, extend entirely through the ferrule 100 from end face to rear side (e.g., along the longitudinal axis of the ferrule). The opening 160 may be configured to receive the optical fiber(s) of the ferrule 100 therethrough, as well as epoxy for curing to set the optical fiber(s). In the depicted embodiment, the opening 160 comprises a single opening configured to receive all optical fibers therethrough followed by individual fiber channels 168 for the individual fibers. In some embodiments, fiber channels 168 may extend individually to the rear side surface of the ferrule 100 without a common opening therebetween. In some embodiments, various other configurations of individual and one or more collective openings may be used for receiving the optical fiber(s) to optimize affixation and routing of the optical fibers. For example, the opening 160 may be divided into multiple separate openings, each configured to receive a subset of one or more of the optical fibers. In some embodiments, instead of a single larger opening transitioning directly to individual channels 168,the ferrule 100 could incorporate an intermediate transition zone with partially separated channels that gradually separate the fibers before entering fully individual channels. In some embodiments, the opening 160 and / or fiber channels 168 could be tapered or funnel-shaped to guide the optical fibers more easily into their respective channels, potentially reducing stress on the fibers during insertion and improving alignment. In some embodiments, the fiber channels 168 may include one or more protrusions similar to the protrusion 172 of the terminal fiber channels 170. In some instances, the fiber channels 168 may be partially open along one longitudinal side (e.g., groove shaped channels rather than enclosed channels) similar to the terminal fiber channels 170.

[0077] Referring to FIGS. 5-6, respective partial and full side cross-sectional views of a lensed ferrule 100 are shown. In the depicted embodiment, the mating surface 138 of the end face 104 may form an end angle 136 relative to the longitudinal axis 112. In the depicted embodiment, the end angle 136 is oblique (e g., non-perpendicular) relative to the longitudinal axis 112, such that the top side 106 of the ferrule 100 extends farther forward than the bottom side 108. Thus, one of the top side 106 or the bottom side 108 has a longer length (the top side 106 in FIG. 6). This angled end face 104 may facilitate easier mating with complementary ferrules or other optical telecommunications structures and reduce back reflections. When two such ferrules 100 are brought together, their angled mating surfaces 138 can align more precisely (e.g., as complementary angles when one ferrule is inverted), potentially reducing air gaps and improving optical coupling efficiency.

[0078] In some embodiments, the lensed ferrule 100 may comprise an optical region 122 defining at least one fiber-side light-permeable surface 124 and at least one end-side light- permeable surface 128 forming a lens surface 126 of the ferrule. In operation, optical signals may be configured to pass through the optical region 122 between the at least one fiber-side light- permeable surface 124 and the at least one end-side light-permeable surface 128 to optically couple an optical fiber adjacent each at least one fiber-side light-permeable surface 124 with a telecommunications structure (e.g., another ferrule) adjacent the end face 104. In some embodiments, the lensed ferrule 100 may comprise a body defining a unitary molded component. In some embodiments, the body of the ferrule 100 may comprise two or more components attached to each other.

[0079] The at least one end-side light-permeable surface 128 may be defined along the end face 104 (e.g., within the lens recess 174). In the depicted embodiment of FIGS. 5-6, the illustratedend-side light-permeable surface 128 is angled at the lens surface(s) 126 to extend farther forward at a side closer to the top side 106 of the ferrule than a side closer to the bottom side 108 of the ferrule 100. This configuration may be flipped when the ferrule 100 is turned upside down, for example, for a mating ferrule. The angle may be configured to improve the releasability of the end-side light-permeable surface 128 during molding and / or to optimize the output / input of optical signals from / into the ferrule 100 (e.g., depending upon the direction of transmission). For example, in the depicted embodiment, the first row 282 extends 0.4mm farther forward than the second row 284. In some embodiments, the first row 282 may extend less than 0.5mm farther forward than the second row 284. In some embodiments, the first row 282 may extend greater than 0.5mm (e.g., 0.5 to 1mm) or less than 0.4mm farther forward than the second row 284. The row pitch may in some embodiments relate to the manufacturing precision to make the required features in close proximity to one another (e.g., on the low side) and on the high side, the ability to spread the rows apart while maintaining part integrity. Based on the end angle 136 of the ferrule 100, the top side 106 of the ferrule may extend farther forward than the end-side light-permeable surface 128 and / or the bottom side 108 of the ferrule. The at least one lens surface formed by the at least one end-side light permeable surface 128 may be configured to refract optical signals 10 passing between the external environment and the optical region 122. In some embodiments, the at least one lens surface formed by the at least one end-side light permeable surface 128 may be concave towards the optical region 122 (also referred to as convex from outside the body 102) and configured to collimate optical signals leaving the optical region (e.g., focus diverging optical signals) and decollimate (e.g., focus) optical signals entering the optical region to a tip of the respective optical fiber in respective terminal fiber channels 170 or respective fiber channels 168 (depending on where the optical fiber stops).

[0080] The optical region 122 may be defined by the boundaries created by the fiber-side light-permeable surface 124 and the end-side light-permeable surface 128 in each optical path (e.g., the path optical signals follow through the body 102). These surfaces may collectively form an enclosed volume within the body 102 through which optical signals can propagate. In some embodiments, the optical region 122 may extend contiguously from the fiber-side light- permeable surface 124 to the end-side light-permeable surface 128, each of which may form exterior surfaces of the body.

[0081] The specific shape of the optical region 122 may vary between different embodiments so long as optical signals are able to propagate along the optical path between the respective endside light-permeable surface and the fiber-side light-permeable surface associated with each respective optical path. While certain geometries may offer particular advantages or configurability options (e.g., adjusting the shape or orientation of the end-side light-permeable surface to control the width or direction of the input / output optical signals or to adjust for various optical output needs), the shape of the optical region 122 need not be constrained in other areas not impacting the optical signal transmission. Various shapes may be employed, provided they allow optical signals to traverse the intended optical path within the optical region 122.

[0082] In some instances, the optical region 122 may be formed from a material that is transparent or near transparent to the wavelengths of light used in the optical signals (e.g., a transparent polymer as discussed herein). This transparency may allow for efficient transmission of optical signals through the ferrule 100. In contrast, other portions of the body 102 outside the optical region 122 may be made from the same material (e.g., for unitarily molded ferrule) or from materials with varying degrees of transparency or opacity. For example, in some embodiments, the areas of the body 102 surrounding the optical region 122 may be opaque or partially opaque, including being made of opaque material or coated with an opaque coating, to help isolate the optical signals and prevent light leakage.

[0083] In some embodiments, the optical region 122 may be a single, contiguous volume that accommodates multiple optical paths with the spacing between paths serving to reduce or eliminate crosstalk. In some embodiments, the end-side light-permeable surface 128 may be a single contiguous piece of material defining respective lens surface 126 shapes therein. In other embodiments, the end face 104 may comprise two or more separate end-side light-permeable surfaces 128, each having one or more lens surfaces 126 formed therein.

[0084] In some embodiments, the lens surface 126 may be configured to collimate the incident optical signals when incident from the optical region 122. The collimation of incident optical signals by the lens surfaces 126 formed by the end-side light-permeable surfaces 128 may enhance the performance and efficiency of the lensed ferrule 100. In an instance in which the lens surfaces 126 of the end-side light-permeable surface(s) 128 collimates the optical signals, the diverging light rays emitted from the optical fiber (e.g., optical fiber 12 shown in FIG. 18) are transformed into parallel rays of optical signal (e.g., for a transmitting ferrule). The collimated beam of opticalsignals 10 may exit the ferrule with various improved properties, including for example, reduced signal loss, improved coupling efficiency, enhanced tolerance to misalignment, a consistent beam profile, and increased compatibility with other optical components. For example, the collimated optical signals may maintain their intensity over longer distances, minimizing signal degradation as the optical signals traverse the gap between the ferrule and the receiving telecommunications structure (e.g., another ferrule). The larger beam profile or cross-section of the optical beam may mitigate issues with misalignment or dust and other obstructions on the ferrule that may otherwise limit the bandwidth and connection strength of the ferrule. The lens collimation capability may be achieved through contouring the shape of the lens surface to reflect all optical signals originating from one light-permeable surface (e.g., the fiber-side light-permeable surface and / or end-side light permeable surface). In various embodiments, the lens surfaces and length of the body between the fibers and lens surfaces may be configured to generate a beam that is convergent, divergent, or collimated, using various lens prescriptions.

[0085] The at least one end-side light-permeable surface 128 may define a normal vector (e.g., a vector perpendicular to its surface of origin) along the direction of the input or output of the optical signals respectively into or out of the ferrule that may define a general orientation of the end-side light-permeable surfaces 128 and the respective lenses. In embodiments in which the at least one end-side light-permeable surface 128 includes concave lenses 126, the normal vector may be defined at a portion of the curved surfaces that define each lens and correspond to the direction of optical signals entering or leaving the ferrule. The end-side light-permeable surface(s) 128 may be configured to receive and / or emit optical signals 10 to / from the optical region 122 in various directions depending upon the intended use case and operation of the ferrule 100.

[0086] In some embodiments, the normal vector and the optical signals entering and / or exiting the ferrule (e.g., in respective receiving and transmitting configurations) may be oriented parallel to the longitudinal axis 112. In some embodiments, the normal vector and / or at least a portion of the optical signals entering and / or exiting the ferrule (e.g., in respective receiving and transmitting configurations) may be oriented at a nonzero angle relative to the longitudinal axis 112 (e.g., not parallel to the longitudinal axis 112). In some embodiments, the lens surfaces may be defined at a height position corresponding to a width axis bisecting the pin axes 134 of the body 102 and defining a horizontal center plane parallel to the longitudinal axis, such that the at least one endside light-permeable surface 128 aligns along the longitudinal axis 112 with a corresponding end-side light-permeable surface 128 of a connected ferrule. The term “align” may refer to optical alignment, mechanical alignment, or both, as will be understood by the context in which such alignment is described. For example, in some embodiments in which optical signals enter and / or exit the ferrule 100 parallel to the longitudinal axis 112, the lenses formed by the end-side light permeable surface(s) 128 may be axially aligned along the longitudinal axis between ferrules. In embodiments in which the optical signals are emitted and / or received by the ferrule 100 at a nonzero angle relative to the longitudinal axis 112, the lenses formed by the end-side light-emitting surface(s) 128 may be offset in the height dimension relative to the width axis to allow the optical paths to align (e.g., higher than the width axis for lenses oriented at least partially downwardly relative to the perspective of the figures). In some embodiments, the nonzero angle may be between ten and thirty degrees. In some embodiments, the nonzero angle may be between fifteen and twenty five degrees. In some embodiments, the nonzero angle may be twenty or twenty two degrees. Example ferrules with angled lenses, such as for improved molding, are shown in U.S. Patent No. 11,768,335, filed November 4, 2020, and entitled “Lensed fiber optic ferrule with simplified molding”, which is incorporated by reference herein. Examples of other ferrules having modified beams, such as for improved eye safety, are shown in U.S. Patent No. 12,007,608, filed March 14, 2023, and entitled “Multi-fiber ferrule with improved eye safety”, which is incorporated by reference herein in its entirety.

[0087] Referring to FIG. 6, the at least one fiber-side light-permeable surface 124 may define an oblique angle relative to the longitudinal axis 112 of the body 102. For example, the portion of the body 102 between the end face 104 and the window 166 may be tapered such that a mold may release easier in the downward direction relative to the orientation of the figure. In the depicted embodiment, the window 166 becomes wider closer to the bottom side 108 with both the forward wall of the window (e.g., the wall that defines the at least one fiber-side light-permeable surface 124) and the rear wall of the window tapered at oblique angles to the longitudinal axis 112 in opposite directions. In the depicted embodiment, the at least one fiber-side light-permeable surface 124 is angled in an opposite direction from the end angle 136 relative to the height dimension 110. Moreover, in the depicted embodiment, the lower-most portion of the end face 104 within the lens recess 174 is angled slightly forward from the lower edge of the end-side light-permeable surface(s) 128. In some embodiments, this lower-most portion may be angled rearward. In eitherinstance, the flexibility of the body 102 in the region between the end face 104 and the window 166 may permit a mold to release without damaging or permanently deforming the body 102.

[0088] Similar to the at least one end-side light-permeable surface 128, each optical path may have a separate fiber-side light-permeable surface, or a single fiber-side light-permeable surface 124 may be used for two or more optical paths respectively corresponding to two or more fibers. In some embodiments, the oblique angle of the at least one fiber-side light-permeable surface 124 may additionally or alternatively be configured to allow optical signals to enter the body 102 and / or the fiber (e.g., depending upon the direction of the signal) with minimal back reflection. An example lensed ferrule with low back reflection and the corresponding position of the ferrule and optical fibers are shown in U.S. Patent No. 12,164,155, filed August 2, 2021, and entitled “Lensed ferrule with low back reflection”, which is incorporated by reference herein in its entirety. The fiber-side light-permeable surface(s) 124 and / or the end-side light-permeable surfaces 128 may comprise an anti-reflective coating.

[0089] Referring to FIGS. 7-12, a multi-row lensed ferrule 200 is illustrated. The multi-row lensed ferrule 200 may include the same features and functionalities as the lensed ferrule 100 (e.g., a single-row lensed ferrule) described with respect to FIGS. 1-6, with some differences to add additional rows as described herein. For example, the multi-row lensed ferrule may have two or more rows of the lenses 226 formed by at least one end-side light-permeable surface 228. Various embodiments may interchangeably use multiple or separate lens elements. For example, other lenses may be molded or otherwise formed in or attached to the body in addition to or instead of the lens surfaces 226 defined by the end-side light-permeable surfaces 228 while having the various optical features discussed herein. The rows are depicted extending in a widthwise direction between pin openings 228 of the ferrule. The multi-row lensed ferrule 200 may include a body 202 defining an end face 204. The body 202 may include a top side 206 and a bottom side 208 defining a height dimension 210 therebetween. A longitudinal axis 212 of the multi-row lensed ferrule 200 may be defined perpendicular to the height dimension 210. The body 202 may further include a first side 214 with a first side surface 216, and a second side 218 with a second side surface 220.

[0090] As shown in FIG. 8, the multi-row lensed ferrule 200 may include multiple rows of end-side light-permeable surfaces 228 (e.g., a first row 282 and a second row 284) arranged along the end face 204. The multiple rows of end-side light-permeable surfaces 228 may allow the multirow lensed ferrule 200 to accommodate a higher density of optical fibers compared to the single-row configuration of the lensed ferrule 100. The body 202 may include pin openings 232 that define pin axes 234, which pin axes may extend parallel to the longitudinal axis 112. The end face 204 may include a lens recess 274 and pin recesses 276 structured and configured to operate as discussed herein with respect to the lensed ferrule 100 (shown in FIGS. 1-6) and light turn lensed ferrule 300, 400, 500 (shown in FIGS. 13-22). A mating surface 238 may be provided on the end face 204. The body 202 may include a top surface 246 and a bottom surface 248, with a top cutout 250 and a bottom cutout 252 defined therein. The body 202 may also include chamfered corners 278 and rounded comers 280.

[0091] Referring to FIG. 9, the body may include a window 266 configured to receive adhesive (e.g., epoxy) and / or improve access to the optical fibers in a similar manner to the singlerow lensed ferrule 100 of FIGS. 1-6. As depicted in FIGS. 9, 11, and 12, in the multi-row lensed ferrule 200, the terminal fiber channels 270 may be longitudinally staggered, with the upper, first row of terminal fiber channels positioned rearward of the lower, second row of terminal fiber channels, creating a tiered effect to facilitate adhesion, molding, and access to the rows of fibers. Such tiering or staggering may also be done to ensure that the optical beams travel the same optical path between lens surfaces 226 and the tips of the optical fibers for each respective row (e.g., manufacturing precision and accuracy). The terminal fiber channels 270 may include protrusions structured and positioned in substantially the same manner as other embodiments discussed herein. The optical fibers may extend between the terminal fiber channels 270 and an opening (e.g., opening 260 shown in FIG. 10) via one or more fiber channels 268. The terminal fiber channels 270 may comprise one or more protrusions 272 to secure the fibers as discussed herein.

[0092] Referring to FIGS. 11-12, the body 202 may include an optical region 222 defining multiple rows of fiber-side light-permeable surfaces 224 corresponding to the multiple rows of end-side light-permeable surfaces 228. While described as rows of light-permeable surfaces, similar to various other embodiments herein, the body 202 may comprise any configuration of one or more fiber-side light-permeable surfaces 224 and / or end-side light-permeable surfaces 228, whether integrally molded as a single piece or formed as separate pieces separated by row, optical path, or the like, so long as such light-permeable surfaces are respectively arranged to receive optical signals from two or more rows of optical fibers and / or two or more rows of lens surfaces formed in a counterpart ferrule. The optical region 222 may comprise three or more lens surfaces 226 to transmit and / or receive optical signals to / from three or more optical fibers at the end-sidelight-permeable surfaces 228. In some embodiments, the three or more lens surfaces may be internally concave within the optical region 222. The three or more lens surfaces may be shaped to collimate optical signals prior to exiting the end-side light-permeable surfaces 228. Alternatively, in the other direction, the end-side light-permeable surfaces 228 is configured to receive collimated beams that are then focused to respective optical fibers terminated inside the body 202. Yet alternatively, bi-directional optical beam transport may occur simultaneously within the body 202. In some embodiments, the lengths 256, 258 of each row of lens surfaces 226 (e.g., fiber-to-lens distance for each row) may cause the beam to be convergent or divergent or both sets of beams could be collimated by applying different lens prescriptions.

[0093] As shown in FIG. 11, the length of the body between the end-side light-permeable surface(s) 228 and the fiber-side light-permeable surface(s) 224 may vary between the rows of lens surfaces 226. For example, the body 202 may define a first length 256 of the optical region 222 along the longitudinal axis 212 between a first lens surface 226 of the first row 282 of lens surfaces of the end-side light-permeable surface(s) 228 and a first fiber-side light-permeable surface of a first row of fiber-side light-permeable surfaces 224. The body 202 may also define a second length 258 of the optical region 222 along the longitudinal axis 212 between a second lens surface 226 of the second row 284 of lens surfaces and a second fiber-side light-permeable surface of a second row of fiber-side light-permeable surfaces. In some embodiments, the first length 256 may be greater than the second length 258. This difference in lengths between the rows may improve molding of the multi-row lensed ferrule 200 by allowing for easier release from a mold (e.g., by tiering the rows of optical paths). For example, in some embodiments, the lengths 256, 258 may be 0.4 mm different (e.g., the first length 256 being 0.4 mm greater than the second length 258). In some embodiments, the lengths 256, 258 may be 0.5 mm different (e.g., the first length 256 being 0.5 mm greater than the second length 258). In some embodiments, the lengths 256, 258 may be 0.6 mm different (e.g., the first length 256 being 0.6 mm greater than the second length 258). In some embodiments, the lengths 256, 258 may be 0.7 mm different (e.g., the first length 256 being 0.7 mm greater than the second length 258). In some embodiments, the lengths 256, 258 may be 0.8 mm different (e.g., the first length 256 being 0.8 mm greater than the second length 258). In some embodiments, the lengths 256, 258 may be 0.9 mm different (e.g., the first length 256 being 0.9 mm greater than the second length 258). In some embodiments, the lengths 256, 258 may be 1 mm different (e.g., the first length 256 being 1 mm greater than the second length 258).In some embodiments, the lengths 256, 258 may be from 0.4 to 1 mm different (e.g., the first length 256 being from 0.4 to 1 mm greater than the second length 258). In some embodiments, the lengths 256, 258 may be from 0.8 to 1 mm different (e.g., the first length 256 being from 0.8 to 1 mm greater than the second length 258). In some embodiments, improved molding may ensure that all optical beams in the respective rows travel the same optical path and arrive at the optical fibers or leave the end-side light-permeable surfaces 228 with similar optical properties (e.g., intensity, convergence, divergence, or collimation, etc.). In some embodiments, the lens surfaces 226 of the first row 282 may have a different lens (e.g., different prescription and / or size) than the lens surfaces of the second row 284.

[0094] In some embodiments in which the first length 256 associated with the first row 282 is different than the second length 258 associated with the second row 284, the body 202 may define different optical properties to account for the difference. For example, a diverging optical signal emanating from an optical fiber along the optical path leading to the first row 282 of lens surfaces 226 may have a greater cross-sectional area when it reaches the end face 204 than a diverging optical signal emanating from an optical fiber along the optical path leading to the second row 284 of lens surfaces 226. In some such embodiments, one or more lenses may be used with different prescriptions to direct the optical signals along the respective optical paths and across the respective exchange zones between ferrules. In some embodiments, one or more lenses (e.g., the first row of lenses) may be larger in size than other lenses (e.g., the second row of lenses) to account for the more dispersed beams of the first row of optical fibers. In some embodiments, lenses associated with the first row 282 and the second row 284 may be the same size with the lenses of the second row 284 at least being larger than the cross-sectional area of an incident optical signal. In some embodiments, the lenses (e.g., lens surfaces 226) of the first row 282 and / or the second row may have prescriptions chosen to direct the optical signals into a corresponding lens from the opposite row (e.g., for inverted, axially mating ferrules). Thus, in embodiments in which the prescription and / or size of the lens surface 226 differs between rows, the respective prescription and / or size may be chosen (e.g., via a converging, collimated, or diverging lens) to direct the optical signal into a particular counterpart lens surface, whether such counterpart is for an axially mating ferrule or a different receiving lens surface (or other surface) of a telecommunications structure. In some embodiments, the lens surfaces 226, lengths 256, 258, and other attributes of the body 202 may be chosen to permit transmission and collection of all or substantially all of theoptical signals emitted by an optical fiber. The foregoing may further apply in situations in which the lenses are not formed at the end face and / or at another surface of the ferrule.

[0095] In the depicted embodiment, the mating surface 238 of the end face 204 may form an end angle 236 relative to the longitudinal axis 212. In the depicted embodiment, the end angle 236 is oblique (e.g., non-perpendicular) relative to the longitudinal axis 212, such that the top side 206 of the ferrule 200 extends farther forward than the bottom side 208. For example, the depicted embodiment includes a twelve degree angle from perpendicular (e.g., end angle 236 is seventy eight degrees relative to the longitudinal axis 212). In some embodiments, the end angle may be eight degrees. In some embodiments, the end angle may be within 5% of twelve degrees (e.g., between 11.4 degrees and 12.6 degrees). In some embodiments, the end angle may be from eight to twelve degrees. In some embodiments, the end angle may be from four to seven degrees. In some embodiments, the end angle may be less than four degrees. The end angle may, in addition to one or more various other angled surfaces described herein, be configured to permit release of the ferrule from a mold (e.g., for molding using actuation of only one core). For example, in the various embodiments and surfaces discussed herein, the ferrule may be structured to not create an undercut for molding (e.g., a unitary mold with actuation of only one core in some examples). This angled end face 204 may facilitate easier mating with complementary ferrules or other optical telecommunications structures. When two such ferrules are brought together (e.g., with one reversed as shown in FIG. 22), their angled mating surfaces 238 can align more precisely, potentially reducing air gaps and improving optical coupling efficiency. Furthermore, the angled end face 204 contributes to the ferrule's ability to redirect light at a nonzero angle relative to the longitudinal axis 212 and may facilitate eye safety, signal transfer efficiency, alignment, noise reduction, and connection quality between the ferrule 200 and another ferrule or other telecommunications structure.

[0096] In operation, the ferrules may be engaged axially by translating two ferrules towards each other along the longitudinal axes 212 and / or pin axes 234 in a similar manner to the other ferrule embodiments discussed herein. Two ferrules may be engaged with their end faces 204 facing towards each other and the ferrules 100 inverted relative to each other (e.g., with the respective top sides 206 of the ferrules facing opposite directions) such that the mating surfaces 238 engage and form a partly or fully light sealed exchange area between the end-side light- permeable surfaces. During such an inverted engagement of ferrules, the first row 282 of lenssurfaces 226 of a first ferrule, which protrudes farther forward than the second row 284 of the first ferrule, may align with and transmit optical signals between a second row 284 of lens surfaces 226 of the second ferrule and vice versa. Thus, in an instance in which inverted ferrules are mated with their end faces facing each other, the optical path distance is the same between both rows (e.g., each optical path must follow a “first length” plus “second length” optical path).

[0097] Turning to FIGS. 13-22, various embodiments of light turn lensed ferrules 300, 400, 500 are depicted. The various features of the various depicted embodiments may be usable with each other and may be interchangeable, in whole or in part. Unless described or depicted otherwise, features disclosed respect to one embodiment may apply to the remaining embodiments. Referring to FIGS. 13-18, an example light turn lensed ferrule 300 is shown. The light turn lensed ferrule 300 may include a body 302 defining an end face 304. In some embodiments, the body 302 may include a top side 306 and a bottom side 308 defining a height dimension 310 therebetween, although the embodiment herein may be equally described by reversing the convention chosen for top and bottom. A longitudinal axis 312 of the light turn lensed ferrule 300 may be defined perpendicular to the height dimension 310. In operation, the light turn lensed ferrule 300 may be inserted into engagement with another ferrule or other telecommunications structure along the longitudinal axis 312 (e.g., as shown in the embodiment of FIG. 22). In some embodiments, the body 302 may have a maximum height dimension 310 of 1.85 mm. The body 302 may have a maximum width dimension of 6.4 mm between a first side 314 and a second side 318. The body 302 may have a maximum length dimension of 4 mm. In some embodiments, the body 302 may be within 5% of 1.85mm tall (e.g., 1.7575mm to 1.9425mm); within 5% of 6.4mm wide (e.g., 6.08mm to 6.72mm); and / or within 5% of 4mm long (e.g., 3.8mm to 4.2mm).

[0098] The body 302 of the light turn lensed ferrule may be constructed from a variety of materials that can be molded and possess at least partial transparency for allowing optical signals to propagate through the optical region(s) (e.g., optical regions 322 described with respect to FIGS. 17-18). In some embodiments, the body 302 may be made from one or more polymers. These polymers may include thermoplastics such as polycarbonate, acrylic (e.g., polymethyl methacrylate or PMMA), polystyrene, cyclic olefin polymer (COP), cyclic olefin copolymer (COC), polysulfone (PSU), or polyether (PEI). For example, at least the optical region of the polymer may be made of an optically transparent or near transparent polymer. In some embodiments, the body 302 may be formed from thermosetting plastics like epoxy resins orpolyurethanes. The body may also be made from composite materials that combine different polymers or incorporate additives to enhance specific properties. For example, the body may be formed from a blend of polycarbonate and polyester to balance optical and mechanical characteristics. In certain embodiments, the body may be constructed using multi-material molding techniques, allowing different regions of the ferrule to be made from distinct materials with complementary properties. This approach may enable optimization of optical, mechanical, and thermal characteristics across different portions of the ferrule body.

[0099] The body 302 may further include a first side 314 with a first side surface 316, and a second side 318 with a second side surface 320. The first side surface 316 may join the top side 306 and the bottom side 308 at the first side 314, and the second side surface 320 may join the top side 306 and the bottom side 308 at the second side 318. While depicted as a single, unitary molded material, in some embodiments, the body 302 may be formed of multiple components (e.g., separately molded or otherwise formed components for a two-piece body) attached to each other, whether permanently, semi-permanently, or temporarily. For example, in some embodiments, one or more lens surfaces may be integrated in a lens plate portion of the body which may be separately attached to a second portion of the body. In such embodiments, the various components of the body may be the same material and / or one or more different materials.

[0100] In some embodiments, the side surfaces, top surface, and bottom surface of the body 302 may not necessarily be connected at perpendicular angles. Instead, as shown in FIGS. 13-18, the body 302 may incorporate various transitional features between these surfaces to enhance the ferrule's functionality, manufacturability, or aesthetic appeal. For example, as illustrated in FIG. 13, the body 302 may include chamfered corners 378 and rounded corners 380 at the intersections of different surfaces. Moreover, in some embodiments, at least a portion of the top surface 346 and bottom surface 348 may be parallel (e.g., the outermost planar portions of the top and bottom surfaces). In other embodiments, the top surface 346 and the bottom surface 348 need not be parallel. Similarly, in some embodiments, at least a portion of the first side surface 316 and the second side surface 320 may be, but are not required to be, parallel.

[0101] The chamfered comers 378 may provide a beveled or angled transition between adjacent surfaces, which may help reduce sharp edges and potential stress concentrations in the ferrule structure. These chamfered transitions may also facilitate easier insertion of the ferrule into a connector housing or mating component. In one embodiment, the chamfered corners 378 maynot exist, i.e., the corners may be sharp or rounded. Similarly, the rounded corners 380 may offer a smooth, curved transition between surfaces. This rounded profile may further contribute to stress reduction, improve the ferrule's durability, and potentially enhance its optical performance by minimizing light scattering at surface intersections. The incorporation of these transitional features may vary depending on the specific requirements of the ferrule design. In some embodiments, chamfered corners 378 may be used at certain intersections while rounded comers 380 are employed at others. The extent and angle of chamfering or the radius of rounding may also be adjusted to suit particular design needs or manufacturing processes. These transitional features may extend along the entire length of the ferrule body 302 or may be localized to specific regions, such as near the end face 304 or at the rear of the ferrule. In the depicted embodiment, having varied comer profiles (e.g., chamfered comers 378 on the bottom side transition and rounded corners 380 on the top side transition) may allow the ferrule to be keyed such that it may only engage a connector housing and / or receiving component (e.g., another ferrule, another connector, or another telecommunications structure) in a single orientation and may provide a visual indicator of polarity. In some embodiments, having chamfered corners 378 on the bottom side transition may facilitate molding via easier to form and / or easier to release shapes.

[0102] In some embodiments, the body 302 may include a top surface 346 defining a top cutout 350 and a bottom surface 348 defining a bottom cutout 352. The top cutout 350 and bottom cutout 352 may be used to secure the ferrule within a connector housing. For example, these cutouts may engage with corresponding protrusions or other features within the connector housing, providing a mechanism for retention and alignment. This engagement may help stabilize the ferrule, particularly in a shoulderless design where traditional flanges or shoulders are absent. The illustrated ferrule 300 is shoulderless as it lacks any type of flange or protrusion extending from the top, bottom, or sides in the rear portion of the body. The ferrule body 302 as illustrated maintains a consistent profile along its length, without the typical outward extensions or shoulders found in conventional ferrule designs. In some embodiments, minor deviations may be formed in the surfaces, such as the cutouts 350, 352 or other indentations without necessarily including a shoulder. A shoulderless design may offer several benefits. It may allow for a more compact form factor, potentially enabling higher density connections in space-constrained environments. The absence of shoulders may simplify the manufacturing process and reduce material usage, and at the same time may reduce the potential of shoulders to break in some instances. The ferrule maybe held within a connector by other features, such as but not limited to one or more cutouts as described herein and / or by other features of the profde of the sides of the body. Additionally, a shoulderless design may facilitate easier insertion and extraction of the ferrule within connector assemblies, which may improve installation efficiency and reduce the risk of damage during handling. In some other embodiments, a shoulder may be added to the ferrule, such as the shoulders shown and described in U.S. 11,768,335, filed November 4, 2020, and entitled “Lensed fiber optic ferrule with simplified molding”, which is incorporated by reference herein.

[0103] With continued reference to FIGS. 13-15, the body 302 may further include at least one pin opening 332 defining a pin axis 334 along which a pin may be configured to extend from the body 302 and / or be inserted into the body. In the depicted embodiment, the light turn lensed ferrule 300 includes two pin openings 332 (e.g., a first pin opening 332 defined at the end face 304 adjacent the first side 314 and a second pin opening 332 defined at the end face 304 on an opposite side of the at least one end-side light-permeable surface 328 from the first pin opening 332 adjacent the second side 318). Pins may be inserted into the pin openings 322 to create a directional ferrule (e.g., two pins engaged with a single ferrule may cause the ferrule to only engage pin-less receiving ferrules) or hermaphroditic ferrule (e.g., one pin engaged with a ferrule may allow the ferrule to engage other one-pin ferrules via inserting the pins into the opposing, pin-less pin openings of the counterpart ferrule). Alternatively, for a hermaphroditic configuration, the ferrule 300 may have a pin-like projection integrally molded and protruded from the end face 304, and have only one pin opening 332 to correspondingly receive a pin-like protrusion from another identical hermaphroditic ferrule. In some embodiments, the pin axis 334 may be parallel to the longitudinal axis 312.

[0104] In the depicted embodiment, the end face 304 of the body 302 may include a mating surface 338 having several recesses or other features formed therein. The recesses may facilitate various structural and optical interactions for the ferrule. For example, the end face 304 of the body 302 may also include a lens recess 374 in which one or more optical components for optical signal transmission are disposed as described herein. The end face 304 may, in some embodiments, define a pin recess 376 at each of the pin openings 332. The pin recesses 376 and lens recess 374 may be configured to prevent portions of a pin, portions of the body, or other structures from preventing the mating surface 338 from sealing against a corresponding mating surface 338 of another ferrule or other telecommunications structure.

[0105] The end face may include various optical surfaces and components to facilitate the lensed light turn functionality described herein. FIGS. 13-15 illustrate a light-turn protrusion 325 that may extend from the end face 304 within the lens recess 374. The lens recess 374 may be configured to interface with the end-side light-permeable surface, and accompanying structure, of another ferrule to permit coupling between two ferrules (e.g., as shown in FIG. 22). Similarly, a transceiver or other telecommunications structure may be configured to insert at least partially into the lens recess 374 to receive optical signals from the ferrule 300 or transmit optical signals into the ferrule. In some embodiments, the light-turn protrusion 325 may be an unstressed portion of the body 302 that does not contact any other component during mating of the ferrule with another ferrule or other telecommunications structure.

[0106] In some embodiments, the light-turn protrusion 325 may incorporate one or more light turn surfaces (e.g., the depicted lens surfaces 326) and the end-side light-permeable surface 328 to facilitate redirection and receipt or emission of optical signals as described herein. Other structures may similarly be used to form the end-side light-permeable surface 328, one or more light-turn surfaces, and / or lens surfaces 326, including using lenses that are discrete (e.g., molded unitarily in another region of the optical region 322 or attached separately) from the light-turn and / or light- permeable surfaces in various embodiments. The embodiments depicted in the figures include lens surfaces 326 that are also light-turn surfaces which both redirect the optical signals to a nonzero angle (e.g., nonzero angle 330) and focus the optical signals (e.g., focus diverging optical signals received from the optical fiber into a collimated, converging, or diverging beam to exit the ferrule and / or focus optical signals received from another ferrule, such as via the end-side light-permeable surface 328, for receipt by an optical fiber). Various embodiments may interchangeably use separate and / or multiple light-turn and lens elements. For example, the light-turn surfaces (e.g., at the location of lens surfaces 326) may be flat reflecting surfaces that redirect the optical signals without changing their focus. In such embodiments, another surface (e.g., the end-side light- permeable surface 328) may define one or more lens surfaces and / or other lenses may be molded or otherwise formed in or attached to the body while having the various optical features discussed herein. In some embodiments, both the lens surfaces 326 and a second lens may be included in the optical region 322.

[0107] In some embodiments, the number of lenses (e.g., lens surfaces 326) may correspond to the number of optical fibers that the ferrule is designed to interface with (e.g., sixteen in thedepicted embodiment). For example, a ferrule configured to accommodate multiple optical fibers may include a corresponding number of lens surfaces to facilitate the transmission of optical signals from each fiber. Moreover, in the depicted embodiment, the end-side light-permeable surface 328 is depicted as a single planar surface optically coupled to each of the lens surfaces 326 within the body 302. In various embodiments, separate end-side light-permeable surfaces may be used. In some embodiments, the lens structure, quantity, or configuration may be varied depending on the specific application and design requirements of the ferrule 300. For example, in some embodiments, single or dual lens surfaces may be used in respective single or dual fiber ferrule configurations. In some embodiments, at least two or more lens surfaces may be used to receive optical signals from and / or direct optical signals to at least two or more optical fibers. In some embodiments, three or more lens surfaces may be used in a three or more fiber ferrule configuration.

[0108] Referring to FIG. 14, in some embodiments, at least a portion of the at least one endside light-permeable surface 328 may face towards a width axis 344 extending between the first pin opening 332 and the second pin opening 332. The width axis 344 may, in some embodiments, bisect the pin openings 332. In the depicted embodiment, the end-side light-permeable surface is disposed below and facing partly towards the width axis 344 (e.g., a normal vector extending from the end-side light-permeable surface intersects a horizontal plane 342 that is parallel to the longitudinal axis 312 and contains the width axis 344). In such embodiments, when two ferrules with the same geometry are engaged as shown in FIG. 22 (e.g., reversed with the top side of one ferrule facing the opposite direction of the other ferrule and inverted with the windows 366 of the ferrules facing opposite directions), the end-side light-permeable surfaces can insert into the respective lens recess 374 of the opposing ferrule without the light-turn protrusions 325 contacting each other. Moreover, in such embodiments, the opposing end-side light-permeable surfaces 328 form an exchange zone (e.g., exchange zone 564 shown in FIG. 22) therebetween.

[0109] Turning to FIG. 15, in some embodiments, the body 302 may include a window 366 that connects to one or more fiber channels (e.g., open sided channels and / or enclosed conduits) through which the optical fibers may extend into the ferrule. The window 366 may serve multiple functions in the ferrule design, including providing access to the optical fibers and facilitating their secure fixation within the ferrule body 302 by allowing insertion and / or overflow space for epoxy. In some embodiments, the window 366 may extend along a portion of the body 302 (e.g., withinthe bottom cutout 352 in the depicted embodiment). This open structure may enable easier manipulation and alignment of the fibers during assembly.

[0110] The window 366 may connect to one or more fiber channels 368, which may guide the optical fibers towards a respective terminal fiber channel 370. The window 366 and / or open portions of the fiber channels may allow for the application of epoxy or other adhesive materials along the fiber path to rigidly secure the optical fibers within the ferrule 300. A gap between the terminal fiber channels 370 and remaining fiber channels 368 (also illustrated in FIG. 18) may be configured to receive a greater volume of the epoxy or other adhesive for better affixation in some instances. When epoxy or another adhesive is introduced into the window 366, it may flow into the connected fiber channels and around and between the optical fibers. This may create a strong bond between the fibers and the ferrule body 302, helping to maintain precise fiber alignment and prevent movement or displacement of the fibers over time. The open nature of the window 366 may allow for controlled application of the adhesive, ensuring thorough coverage and minimizing the risk of air bubbles or voids in the epoxy, after the epoxy has been cured in an oven. The window 366 may also facilitate post-assembly inspection and quality control processes. The open structure may allow for visual confirmation of proper fiber placement and adhesive distribution, potentially improving manufacturing reliability and consistency.[0U1] In some embodiments, the terminal fiber channels 370 may be designed to precisely position the end of each optical fiber relative to the fiber-side light-permeable surface 324 of the body 302. In the depicted embodiment, the terminal fiber channels 370 each include a protrusion 372 extending at least partly circumferentially around the interior surface of the channels. The protrusions 372 may define a narrower cross-sectional area that serves to further secure and reliably position the ends of the optical fibers within the terminal fiber channels 370. The protrusions 372 may be at least partially spaced from the fiber-side light-permeable surface(s) 324 of the body 302 to avoid contacting the farthest distal ends of the optical fibers. For example, in some instances, forming the ends of the optical fibers may cause distortions to the shapes of the fibers, such as mushrooming or bulging at the ends. Spacing the protrusions 372 from the fiberside light-permeable surface(s) 324 of the body 302 may avoid contact between these deformed portions of the optical fibers and the protrusions. In some embodiments, as discussed herein, the optical fibers may be positioned with a gap between the distal ends of the optical fibers and the fiber-side light-permeable surface(s) 324.

[0112] Referring to FIG. 16, the body 302 may further define at least one opening 360 at a rear side thereof opposite the end face, and the pin openings 332 may, but are not required to, extend entirely through the ferrule 300 from end face to rear side (e.g., along the longitudinal axis of the ferrule). The opening 360 may be configured to receive the optical fiber(s) of the ferrule 300 therethrough. In some embodiments, the openings may be disposed in another location on the body (e.g., at the top side) with the optical fibers configured to enter the ferrule body from the top. For example, a two piece ferrule body may, in some instances, receive the optical fiber(s) from the top side. In such embodiments, the axis of the optical fiber entering the ferrule may be non-parallel to the longitudinal axis extending through the end face. The optical fibers may be parallel to each other in any of the foregoing examples. In some embodiments, the optical fiber(s) may be normal or not normal to the rear of the ferrule. In the depicted embodiment, the opening 360 comprises a single opening configured to receive all optical fibers therethrough followed by individual fiber channels 368 for the individual fibers. When the ferrule 300 is a two-piece and is split along the horizontal plane 342 , the optical fibers may be positioned into the body 302 from the top (instead of longitudinal insertion), and the second piece (“cap”) attached thereafter. In some embodiments, fiber channels 368 may extend individually to the rear side surface of the ferrule 300 without a common opening therebetween. In some embodiments, various other configurations of individual and one or more collective openings may be used for receiving the optical fiber(s) to optimize affixation and routing of the optical fibers. For example, the opening 360 may be divided into multiple separate openings, each configured to receive a subset of one or more of the optical fibers. In some embodiments, instead of a single larger opening transitioning directly to individual channels 368, the ferrule 300 could incorporate an intermediate transition zone with partially separated channels that gradually separate the fibers before entering fully individual channels. In some embodiments, the opening 360 and / or fiber channels 368 could be tapered or funnel-shaped to guide the optical fibers more easily into their respective channels, potentially reducing stress on the fibers during insertion and improving alignment. In some embodiments, the fiber channels 368 may include one or more protrusions similar to the protrusion 372 of the terminal fiber channels 370. In some instances, the fiber channels 368 may be partially open along one longitudinal side (e.g., groove shaped channels rather than enclosed channels) similar to the terminal fiber channels 370.

[0113] Referring to FIGS. 17-18, respective partial and full side cross-sectional views of a light turn lensed ferrule 300 are shown. In the depicted embodiment, the mating surface 338 of the end face 304 may form an end angle 336 relative to the longitudinal axis 312. In the depicted embodiment, the end angle 336 is oblique (e.g., non-perpendicular) relative to the longitudinal axis 312, such that the top side 306 of the ferrule 300 extends farther forward than the bottom side 308. This angled end face 304 may facilitate easier mating with complementary ferrules or other optical telecommunications structures. When two such ferrules are brought together (e.g., with one reversed as shown in FIG. 22), their angled mating surfaces 338 can align more precisely, improving optical coupling efficiency. Furthermore, the angled end face 304 contributes to the ferrule's ability to redirect light at a nonzero angle relative to the longitudinal axis 312 and may facilitate eye safety, signal transfer efficiency, alignment, noise reduction, and connection quality between the ferrule 300 and another ferrule or other telecommunications structure.

[0114] In some embodiments, the light turn lensed ferrule 300 may comprise an optical region 322 defining at least one fiber-side light-permeable surface 324, at least one lens surface 326, and at least one end-side light-permeable surface 328. The at least one end-side light-permeable surface 328 may be defined along the end face 304 (e.g., at least partially within the lens recess 374). In the depicted embodiment, the end-side light-permeable surface 328 extends farther forward than the bottom side 308 of the ferrule 300 and the top side 306 of the ferrule 300 extends farther forward than the end-side light-permeable surface. The at least one lens surface 326 may be configured to reflect optical signals 10 within the optical region 322 from the at least one fiberside light-permeable surface 324 towards the at least one end-side light-permeable surface 328 and / or reflect optical signals 10 within the optical region 322 from the at least one end-side light- permeable surface 328 towards the at least one fiber-side light-permeable surface 324. In some embodiments, the lens surface(s) 326 may be totally internally reflective of the optical signals. In some embodiments, the density gradient (also referred to as a refractive index differential) between the ferrule body 302 and the outside environment facilitates the total internal reflection. In some embodiments, one or more coatings or other reflective substrates may be coated on the lens surface(s) 326 to further facilitate reflection of the optical signals.

[0115] The optical region 322 may be defined by the boundaries created by the fiber-side light-permeable surface 324, the end-side light-permeable surface 328, and the lens surface 326 in each optical path (e.g., the path optical signals follow through the body 302). These surfaces maycollectively form an enclosed volume within the body 302 through which optical signals can propagate. In some embodiments, the optical region 322 may extend contiguously from the fiberside light-permeable surface 324 to the end-side light-permeable surface 328, with the lens surface 326 forming a reflective boundary along one side. In the depicted embodiment, the lens surface 326 also forms an exterior surface of the body 302 at the end face 304. The refractive index difference between the interior of the optical region 322 of the body 302 and the air external to the body, as well as an angle of the lens surface 326 relative to the longitudinal axis 312, may assist with reflecting the optical signals off the lens surface 326.

[0116] The specific shape of the optical region 322 may vary between different embodiments so long as optical signals are able to propagate along the optical path between the respective endside light-permeable surface and the fiber-side light-permeable surface via the lens surface associated with each respective optical path. While certain geometries may offer particular advantages or configurability options (e.g., adjusting the lens surface angle and / or end-side light- permeable surface angle to make the ferrule eye safe or adjust for various optical output needs), the shape of the optical region 322 need not be constrained in other areas not impacting the optical signal transmission. Various shapes may be employed, provided they allow optical signals to traverse the intended optical path within the optical region 322.

[0117] In some instances, the optical region 322 may be formed from a material that is transparent or near transparent to the wavelengths of light used in the optical signals (e.g., a transparent polymer as discussed herein). This transparency may allow for efficient transmission of optical signals through the ferrule 300. In contrast, other portions of the body 302 outside the optical region 322 may be made from the same material or from materials with varying degrees of transparency or opacity. For example, in some embodiments, the areas of the body 302 surrounding the optical region 322 may be opaque or partially opaque, including being made of opaque material or coated with an opaque coating, to help isolate the optical signals and prevent light leakage.

[0118] In some embodiments, the optical region 322 may be a single, contiguous volume that accommodates multiple optical paths with the spacing between paths serving to reduce or eliminate crosstalk.

[0119] The at least one lens surface 326 may be configured to reflect optical signals within the optical region 322 from the at least one fiber-side light-permeable surface 324 towards the at least one end-side light-permeable surface 328 at a nonzero angle 330 relative to the longitudinalaxis 312. In some embodiments, the nonzero angle 330 may define an oblique angle relative to the longitudinal axis 312. For example, the oblique angle may be less than ninety degrees relative to the longitudinal axis 312 when measured from a forward direction (or greater than ninety degrees in the rearward measurement orientation shown in FIGS. 17-18). In some embodiments, the nonzero angle 300 may be greater than ninety degrees relative to the longitudinal axis 312 when measured from a forward direction. In some embodiments, the nonzero angle 300 may equal ninety degrees.

[0120] In some embodiments, the nonzero angle may vary between optical signals 10 traveling along the same optical path (e.g., interacting with the same lens surface) based on the relative incident direction of the optical signals and the slightly different propagation directions of the optical signals entering the optical region 322 from either the end-side light-permeable surface or the fiber-side light-permeable surface. The nonzero angle may additionally or alternatively vary between optical signals 10 traveling along the same optical path (e.g., interacting with the same lens surface) based on reflected direction of the optical signals and orientation of the lens surface at the particular location of the lens surface that the optical signals reflect from. The nonzero angle 330 may be parallel (i.e., the optical beams may be parallel) to a portion 354 of the end face 304 adjacent the at least one end-side light-permeable surface 328 and perpendicular to the at least one end-side light-permeable surface 328. In some embodiments, the nonzero angle 330 may be nonperpendicular to the at least one end-side light-permeable surface 328. In some embodiments, the nonzero angle 330 may be nonparallel to the portion 354 of the end face 304 adjacent to the at least one end-side light-permeable surface 328. The nonzero angle may be configured to allow total internal reflection (TIR) of the optical signals 10 based on the index change between the ferrule 300 material and the air external to the ferrule. In some embodiments, a reflective coating may be applied to the exterior of the body 302 at the lens surface 326 to further facilitate reflection, including reflection outside the optimal TIR range.

[0121] In some embodiments, the lens surface may be configured to collimate the incident optical signals when reflecting them. The collimation of incident optical signals by the lens surface 326 may enhance the performance and efficiency of the light turn lensed ferrule 300. When the lens surface reflects and collimates the optical signals, it transforms the diverging light rays emitted from the optical fiber 12 into parallel rays of optical signal. The collimated beam of optical signals 10 may exit the ferrule with various improved properties, including for example, reduced signalloss, improved coupling efficiency, enhanced tolerance to dust and debris, a consistent beam profile, and increased compatibility with other optical components. For example, the collimated optical signals may maintain their intensity over longer distances, minimizing signal degradation as the optical signals traverse the ferrule and / or the gap between the ferrule and a receiving telecommunications structure (e.g., another ferrule). The improved signal quality and consistency may mitigate issues with misalignment or dust and other obstructions on the ferrule that may otherwise limit the bandwidth and connection strength of the ferrule. The lens surface's 326 collimation capability may be achieved through contouring the shape of the lens surface to reflect all optical signals originating from one light-permeable surface (e.g., the fiber-side light-permeable surface and / or end-side light permeable surface). In various embodiments, the lens surfaces and length of the body between the fibers and lens surfaces may be configured to generate a beam that is convergent, divergent, or collimated, using various lens prescriptions.

[0122] The at least one end-side light-permeable surface 328 may define a normal vector (e.g., a vector perpendicular to its surface) that may define a general orientation of the end-side light- permeable surface 328. The normal vector in some instances may correspond to the output direction of the optical signals 10 leaving the ferrule 300. In some embodiments, the direction of the optical signals 10 leaving or entering the ferrule need not be perpendicular to the end-side light- permeable surface 328 or parallel to the normal vector. In some embodiments, the normal vector may be oriented sixty to eighty degrees relative to the longitudinal axis. In the depicted embodiment, the normal vector is parallel to a portion 354 of the end face 304 adjacent the at least one end-side light-permeable surface 328, which is within the lens recess 374. In some embodiments, the normal vector may be parallel to the light beam direction entering or exiting the end-side light-permeable surface 328. In some embodiments, the normal vector may be at an angle that is different than an angle of the light beams without causing excessive reflections of the optical beams (e.g., from zero to ten degrees different than the angle of the optical signals 10 exiting or entering the end-side light-permeable surface, such as plus or minus ten degrees).

[0123] The end-side light-permeable surface 328 may be configured to receive and / or emit optical signals 10 to / from the optical region 322 in various directions depending upon the intended use case and operation of the ferrule 300. For example, the embodiment shown in FIG. 17 illustrates an eye safe configuration of the ferrule in which the optical signals 10 are directed back towards the body 302 so that the optical signals travel through the external environment for amaximum of the distance from the end-side light-permeable surface to the surface of the body (e.g., the end face 304) that the optical signals 10 shown absorbing and / or scattering the optical signals. The overhang of the top side 308 may further be used to improve eye safety and connection strength in some embodiments by providing additional volume in which to make the optical connection between ferrules without risking optical signals harming a user’s eye.

[0124] In some other embodiments (e.g., as shown in FIG. 20), the optical signals 10 may exit the vertical footprint of the ferrule 400 without being absorbed by the body. For example, if the optical signals must be transmitted vertically past the body 402, the end-side light-permeable surface 428 and lens surface 426 may be oriented to transmit the optical signals past the body and out indefinitely into the external environment. For example, the embodiment of FIG. 20 illustrates the end-side light-permeable surface 428 having a normal vector oriented closer to horizontal (e.g., closer to the longitudinal axis) than the embodiment of FIGS. 17-18. In the embodiment of FIG. 20, the optical signals 10 may travel parallel to the portion 454 of the end face 404 adjacent the at least one end-side light-permeable surface 428. In some embodiments, the ferrule may be configured to transmit the optical signals in any direction, including parallel to one or more surfaces of the end face 404 (e.g., the mating surface 438), the portion 454 or another surface or including divergent directions from one or more respective end face surfaces. In some embodiments, the normal vector of the at least one end-side light-permeable surface 328 may be oriented parallel to a plane of the mating surface or another surface of the body, in a direction intersecting (e.g., towards) a surface of the body (e.g., as shown in FIG. 17), or in a direction diverging from a surface of the body, which may vary the optical output or reception properties of the ferrule.

[0125] Referring back to FIG. 18, the at least one fiber-side light-permeable surface 324 may define an oblique angle relative to the longitudinal axis 312 of the body 302. For example, the portion of the body 302 between the end face 304 and the window 366 may be tapered such that a mold may release easier in the downward direction relative to the orientation of the figure. In the depicted embodiment, the window 366 becomes wider closer to the bottom side 308 with both the forward wall of the window (e.g., the wall that defines the at least one fiber-side light-permeable surface 324) and the rear wall of the window tapered at oblique angles to the longitudinal axis 312 in opposite directions. In the depicted embodiment, the at least one fiber-side light-permeable surface 324 is angled in an opposite direction from the end angle 336 relative to the heightdimension 310. Similar to the end-side light-permeable surface 328, each optical path may have a separate, fiber-side light-permeable surface or a single fiber-side light-permeable surface may be used for two or more optical paths corresponding to two or more fibers 12. In some embodiments, the oblique angle of the at least one fiber-side light-permeable surface 324 may additionally or alternatively be configured to allow optical signals to enter the body 302 and / or the fiber 12 (e.g., depending upon the direction of the signal) with minimal to no back reflection.

[0126] FIGS. 19-20 illustrate a second embodiment of a light turn lensed ferrule 400. Unless noted or shown otherwise, the light turn lensed ferrule 400 of FIGS. 19-20 may include any feature or property of the other light turn lensed ferrules disclosed herein, in whole or in any subcombination. Similarly, the features and properties of the light turn lensed ferrule 400 of FIGS. 19-20 may be incorporated, in whole or in any subcombination, into the other light turn lensed ferrule embodiments disclosed herein. The depicted light turn lensed ferrule 400 includes a body 402 with an end face 404 similar to the other embodiments discussed herein. The light turn lensed ferrule 400 lacks cutouts at the top and bottom sides but may be modified to include such cutouts or may use other means to secure the ferrule to a connector housing (e.g., clips, welding, adhesive, protrusions, or the like).

[0127] Referring to FIG. 19, the light turn lensed ferrule 400 further includes a mating surface 438, a lens recess 474, and pin recesses 476 that include different shapes than the embodiment of FIGS. 13-18 to illustrate alternative structures. The mating surface 438, a lens recess 474, and pin recesses 476 may generally serve the same purpose as the other respective mating surfaces, lens recesses, and pin recesses disclosed herein, including prevention of dust and debris affecting signal quality and forming a seal around the at least one end-side light-permeable surface 428 to form an enclosed exchange zone with other ferrules via mating of the mating surfaces 438. Turning to FIG. 20, the depicted ferrule 400 further includes at least one optical region 422 with a corresponding at least one fiber-side light-permeable surface 424, at least one lens surface 426, and the at least one end-side light-permeable surface forming one or more optical paths operable to transmit, turn, and / or collimate optical signals 10 as disclosed similarly in various embodiments herein.

[0128] With continued reference to FIG. 20, the optical signals are depicted being emitted by or transmitted into the end-side light-permeable surface in a collimated path perpendicular to a portion 454 of the end face 404 adjacent the at least one end-side light-permeable surface. The depicted optical signals are further emitted at a nonzero angle relative to the longitudinal axis 412that cause the optical signals to not be absorbed by the body 402 (e.g., not passively eye safe). Such embodiments may be used to transmit optical signals to a receiving device (e.g., a ferrule, transceiver, or other telecommunications structure) that is vertically displaced from the ferrule, or for use cases not needing or desiring eye safety (e.g., in a connector in which the connector housing blocks a portion of the exiting optical signals, making absorption by the body 402 unnecessary). An example of such a connector is shown in U.S. Patent No. 12,007,608, filed March 14, 2023, and entitled “Multi-fiber ferrule with improved eye safety”, which is incorporated by reference herein in its entirety. In some embodiments, a second device, such as an interposer (e.g., a mechanical optical interface), may be coupled with the ferrule to focus and / or redirect the optical signals between the ferrule and a telecommunications structure.

[0129] FIGS. 21-22 illustrate a third embodiment of a light turn lensed ferrule 500. Unless noted or shown otherwise, the light turn lensed ferrule 500 of FIGS. 21-22 may include any feature or property of the other light turn lensed ferrules disclosed herein, in whole or in any subcombination. Similarly, the features and properties of the light turn lensed ferrule 500 of FIGS. 21-22 may be incorporated, in whole or in any subcombination, into the other light turn lensed ferrule embodiments disclosed herein. In the depicted embodiment, the light turn lensed ferrule 500 includes a body 502 with an end face 504, the end face defining a lens recess 574 and two pin recesses 576 as discussed with respect to various other embodiments of ferrules herein.

[0130] Referring to FIG. 21, a light turn protrusion 525 is shown having a greater height (e.g., a greater distance between the lens surfaces 526 and the end-side light-permeable surface 528 along the height dimension) than the embodiments of FIGS. 13-20. The operation of the ferrule 500 is unchanged relative to the embodiments of FIGS. 13-20, including the at least one end-side light-permeable surface 528 being disposed below and oriented at least partially towards a width axis at a height position that facilitates coupling of the ferrule with another ferrule or other telecommunications structure as described herein.

[0131] Referring to FIG. 22, two identical ferrules 500a, 500b having the same construction as the embodiment of FIG. 21 are shown, with letters “a” and “b” referring to the components of each respective ferrule and letterless reference numerals referring generically to either. As illustrated, the two ferrules 500a, 500b are in an engaged configuration with the ferrules reversed and inverted relative to each other (e.g., the ferrules 500a, 500b are facing each other with their respective windows 566a, 566b facing opposite height directions). These mirrored positions allowthe end-side light-permeable surfaces 528a, 528b to be held parallel to each other with a small gap therebetween defining an exchange zone 564 therebetween. In some embodiments, the gap may be larger or smaller (or eliminated entirely) while permitting transmission of optical signals 10 between the two ferrules 500a, 500b.

[0132] The engagement zone 564 between the ferrules 500a, 500b may be partly or completely sealed (e.g., partly or entirely blocking light leakage into or out of the engagement zone) via the engagement of the mating surfaces 538 about the periphery of the lens recesses. The mating surfaces may be planar and angled at the end angle of the ferrule to engage a corresponding flat mating surface of a connecting ferrule or other telecommunications structure.

[0133] As depicted, in operation, the optical signals 10 may enter either ferrule 500a, 500b from an optical fiber via the respective fiber-side light-permeable surface 524a, 524b of the transmitting ferrule; travel through the optical region 522a, 522b of the transmitting ferrule; reflect and collimate at the lens surface 526a, 526b of the transmitting ferrule; pass through the end-side light-permeable surface 528a, 528b of the transmitting ferrule into the exchange zone 564; pass through the end-side light-permeable surface 528a, 528b of the receiving ferrule into the optical region 522a, 522b of the receiving ferrule; reflect and are focused (e.g., decollimated) at the lens surface 526a, 526b of the receiving ferrule; pass through the fiber-side light-permeable surface 524a, 524b of the receiving ferrule; and enter the optical fiber connected to the receiving ferrule. In some embodiments, the end-side light-permeable surface 328 and / or fiber-side light-permeable surface 324 may have an anti-reflective coating. In some embodiments, the end-side light- permeable surface 328 and / or fiber-side light-permeable surface 324 may have either an anti- reflective coating or may be angled relative to the optical signals incident on either side of the respective surfaces. For example, the end-side light-permeable surface 328 may include an anti- reflective coating and the fiber-side light-permeable surface 324 may lack an anti-reflective coating in some embodiments.

[0134] As shown in FIGS. 21-22, collimation of the optical signals 10 in the light turn lensed ferrule 500 may provide advantages for both transmitting and receiving signals. In some embodiments, signals enter a receiving ferrule at the end-side light-permeable surface in a collimated state (e.g., having been emitted from a collimated source, such as another ferrule). The lens surface 526 may be configured to collimate or decollimate the optical signals 10 dependingupon the direction from which the signals are received to facilitate bidirectional collimated communication across the exchange zone 564.

[0135] The optical path and functionality of the various lensed ferrule configurations may vary depending on the specific shape and intended input and / or output properties. In general, an optical signal may travel bidirectionally through the lensed ferrule, allowing for both transmission and reception of optical signals. The collimated nature of the optical signals may facilitate the axial coupling of the ferrules by relaxing certain dimensional constraints within the ferrule structure. For example, the height between the lens surface and the end-side light-permeable surface, as well as the gap in the exchange zone between mating ferrules, become less critical with a collimated beam, which maintains its signal strength without requiring a specific focal distance and while being tolerant to variations in alignment and distance compared to divergent beams. Thus, the ferrules can be coupled via purely axial insertion (e.g., along each ferrule's respective longitudinal axis) and produce a reliable connection across the exchange zone 564.

[0136] Moreover, axial engagement between the ferrules 500a, 500b offers several benefits for optical connector systems. For example, the ferrules 500a, 500b may have a simplified, mechanically stronger connection process with reduced degrees of freedom of motion or need for complex locking movements. The axial insertion also allows for a more compact design, allowing connectors to be inserted next to each other in a larger telecommunications structure at greater connection densities (e.g., less than the height of a connector or less than the height of a ferrule between adjacent connectors) without requiring significant space in the height or width directions for perpendicular movement. For example, in some embodiments, the light turn lensed ferrules (e.g., ferrules 300, 400, 500) disclosed herein may be usable with a multiport MMC brand adapter provided by U.S. Conec Ltd. The axial insertion of the ferrules may also allow for more secure, durable, reliable, accurate coupling via the axially engaging pins discussed herein, and the ferrules may be used with various automated processes due to the simplicity of the engagement.

[0137] The lensed ferrules described herein (e.g., lensed ferrules 100, 200, 300, 400, 500 illustrated in FIGS. 1-22) may be manufactured through various processes and using various single or multi-material constructions to achieve the desired optical and structural properties, including those disclosed herein. In some embodiments, the body of the respective ferrules may be formed as a unitary molded structure. In some embodiments, the body may comprise multiple pieces that are assembled together. This multi-piece construction may provide flexibility in material selectionfor different components and potentially simplify the molding process for complex geometries. When manufacturing the ferrules as a unitary structure or as separate pieces, various polymers may be suitable for injection molding. These polymers may include any of the materials described herein. The selection of material may depend on factors such as optical clarity, mechanical strength, and moldability. In some embodiments, the optical region of the ferrule may be made from a transparent or near-transparent polymer to allow efficient transmission of optical signals.

[0138] The manufacturing process may involve injecting at least one polymer into one or more molds to form the ferrule. The mold(s) may comprise a plurality of surfaces configured to cause the polymer to form the ferrule with specific features as described throughout this disclosure, and the mold(s) may have an inverse shape that matches the illustrated ferrules.

[0139] To facilitate the molding process and ensure reliable production, the ferrules may be designed with considerations for mold release. In some embodiments, the body may be structured to improve molding, with tiered and / or angled surfaces designed to allow even a unitary body to release from the mold. For example, certain surfaces of the ferrule body may be tapered or angled in a single direction (e.g., towards the bottom of the ferrule) to allow the molds to release more easily and without any undercutting. This design approach may help prevent damage to the molded parts during extraction and may improve overall manufacturing efficiency and yield of the ferrules during production. The use of angled or tapered surfaces in the ferrule design may also serve functional purposes beyond manufacturability. For instance, these features may contribute to the optical performance of the ferrule by influencing the path of light through the body or by facilitating alignment with mating components.

[0140] In manufacturing processes involving multiple pieces, each component may be molded separately and then assembled. This approach may allow for optimization of material properties for different parts of the ferrule. For example, the optical region may be molded from a highly transparent polymer, while other structural components may use materials selected for strength or durability.

[0141] FIG. 23 illustrates a perspective view of a connector 28. The connector 28 includes a connector housing 16 that comprises a first connector housing component 18 and a second connector housing component 20. A latch assembly 22 may be integrated into the connector housing 16, and a boot assembly 24 may extend from the rear portion of the connector housing. In some embodiments, a fiber optic cable 26 may pass through the boot assembly 24 to engage aferrule (e g., any of the ferrule embodiments 100, 200, 300, 400, 500 disclosed herein, including the depicted light turn lensed ferrule 300).

[0142] The connector 28 may incorporate a light turn lensed ferrule 300 that extends through a front opening of the connector housing 16. The light turn lensed ferrule 300 may be positioned between the first connector housing component 18 and the second connector housing component 20. In the depicted embodiment, the connector housing 16 may be assembled by inserting the ferrule 300 through the front opening of the first connector housing component 18 and subsequently engaging the second connector housing component 20 with the first connector housing component 18 to lock the ferrule therein. The first connector housing component 18 and second connector housing component 20 may be configured to enclose and protect the components of the connector, including the ferrule 300, while providing structural support for the assembly and the user's operation thereof. Another example connector and related components and processes that may additionally or alternatively be used with various embodiments of ferrule disclosed herein are shown and described in U.S. Patent No. 12,019,278, filed April 23, 2021, and entitled “Miniature multi-fiber ferrule”, which is incorporated by reference herein in its entirety.

[0143] The latch assembly 22 may be positioned on an upper portion of the connector housing 16 and may be configured to engage one or more receptacles or other telecommunications structures for securing the connector therein. Example receptacles (also referred to as adapters) and related processes, components, and assemblies are shown and described in International Publication WO2024 / 158761, filed January 23, 2024, and entitled “Very Small Form Factor Shuttered Fiber-Optic Adapter”, which publication is incorporated by reference herein in its entirety. The fiber optic cable 26 may include one or more optical fibers therein (e.g., optical fiber 12 illustrated in FIG. 18). The boot assembly 24 and the connector housing 16 may define a passageway along their longitudinal lengths to receive the fiber optic cable 26 therethrough to engage the ferrule 300 with the one or more optical fibers. The connector 28 may be designed to facilitate easy insertion and removal from a corresponding receptacle or other telecommunications structure. The latch assembly 22 may allow for secure attachment and quick release when needed. In some embodiments, the boot assembly 24 may provide strain relief for the fiber optic cable 26 and may help protect the cable from bending or other physical stresses. Other types of fiber optic connectors or protective housings around the lensed ferrules 100, 200, 300, 400, 500 maybe used.

[0144] FIG. 24 illustrates a flowchart of an example method 600 for manufacturing a connector, which includes methods of molding several components of the connector. The method 600 begins with step 602, which involves molding a lensed ferrule. This step may include injecting a polymer into a mold to form the ferrule body with the various features described throughout this disclosure, such as the optical region, light-permeable surfaces, and various structural elements. Following this, the method 600 proceeds to step 604, which involves molding a first connector housing component. This step may include forming a portion of the connector housing that will eventually contain and support the lensed ferrule. The method 600 then continues to step 606, where a second connector housing component is molded. This step may involve creating another portion of the connector housing that, when combined with the first component, will fully enclose and secure the lensed ferrule. Steps 602, 604, and 606 may be performed in any order. The method 600 concludes with step 608, which involves assembling the connector by inserting the lensed ferrule between the first connector housing component and the second connector housing component. This final step may include aligning the ferrule within the housing components (e.g., a protrusion on the connector engaging with the respective cutouts in a ferrule), securing it in place, and ensuring proper orientation for optical signal transmission.

[0145] In some embodiments, the method 600 may include additional steps or sub-steps not explicitly shown in FIG. 24. For example, the method may involve applying coatings to certain surfaces of the ferrule or housing components, attaching optical fibers to the ferrule, or performing quality control checks at various stages of the assembly process.

[0146] Various components including the ferrules 100, 200, 300, 400, 500 described herein may be sold as a bag of parts or in a packaging tray for ferrules, which are then assembled by cable assembly houses to form the final fiber optic connector, connector assembly, or other assembly with optical fibers terminated therein. In some instances, the bag of parts will not have any optical fibers or cables. The components in the bag of parts may be provided as partly assembled or as individual non-assembled components for shipping and subsequent assembly.

[0147] While particular structural configurations are shown, they are to be interpreted broadly and interchangeably with the other embodiments herein. The above descriptions of various embodiments of the subject disclosure and corresponding figures and what is described in the Abstract, are described herein for illustrative purposes, and are not intendedto be exhaustive or to limit the disclosed embodiments to the precise forms disclosed. It is to be understood that one of ordinary skill in the art may recognize that other embodiments having modifications, permutations, combinations, and additions may be implemented for performing the same, similar, alternative, or substitute functions of the disclosed subject matter, and are therefore considered within the scope of this disclosure. Therefore, the disclosed subject matter should not be limited to any single embodiment described herein, but rather should be construed in breadth and scope in accordance with the appended claims below and in accordance with the various embodiments disclosed herein. Moreover, although the foregoing descriptions and the associated drawings describe example embodiments in the context of certain example combinations of elements and / or functions, it should be appreciated that different combinations of elements and / or functions may be provided by alternative embodiments without departing from the scope of the appended claims. In this regard, for example, different combinations of elements and / or functions than those explicitly described above are also contemplated as may be set forth in some of the appended claims, and various elements and / or functions may be added or omitted from those embodiments explicitly described above are also contemplated as may be set forth in some of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

CLAIMS1. A ferrule for a fiber optic connector, the ferrule comprising: a body defining: an end face; a top side and a bottom side defining a height dimension of the body therebetween with a longitudinal axis of the ferrule defined perpendicular to the height dimension, the end face defined between the top side and the bottom side, the top side and the bottom side extending rearwardly from the end face; a first side surface joining the top side and the bottom side on a first side of the body and a second side surface joining the top side and the bottom side on a second side of the body opposite the first side; and an optical region defining at least one fiber-side light-permeable surface, at least one lightturn surface, and at least one end-side light-permeable surface; the at least one end-side light- permeable surface defined along the end face; wherein the at least one light-turn surface is configured to reflect optical signals from the at least one fiber-side light-permeable surface towards the at least one end-side light-permeable surface at a nonzero angle relative to the longitudinal axis, and wherein the optical region is configured to at least partly focus the optical signals.

2. The ferrule of claim 1, wherein the at least one light-turn surface defines at least one lens surface, wherein the optical region is configured to at least partly focus the optical signals via the at least one lens surface.

3. The ferrule of claim 1, wherein the at least one end-side light-permeable surface defines at least one lens surface, wherein the optical region is configured to at least partly focus the optical signals via the at least one lens surface.

4. The ferrule of claim 1, wherein the body has a maximum height dimension of 1.85 mm between the top side and the bottom side and a maximum width dimension of 6.4 mm between the first side and the second side.

5. The ferrule of claim 1, wherein the at least one end-side light-permeable surface extends farther forward relative to the longitudinal axis than at least the bottom side of the body.

6. The ferrule of claim 1, the body further comprising at least one pin opening defining a pin axis along which a pin is configured to extend from the body, and wherein the pin axis is parallel to the longitudinal axis.

7. The ferrule of claim 1, wherein the longitudinal axis and at least a portion of the end face form an oblique angle.

8. The ferrule of claim 7, wherein the longitudinal axis and a mating surface of the end face form the oblique angle.

9. The ferrule of claim 8, wherein the at least one end-side light-permeable surface defines a normal vector oriented parallel to a plane of the mating surface.

10. The ferrule of claim 8, wherein the mating surface is planar and reversible, such that the mating surface of the ferrule is configured to abut a second mating surface of a second ferrule having opposing oblique angles, and wherein the mating surface is configured to form a circumferential seal with the second mating surface to prevent the optical signals from escaping.

11. The ferrule of claim 8, wherein the mating surface is opaque.

12. The ferrule of claim 1, wherein the at least one light-turn surface is totally internally reflective of the optical signals received from the at least one fiber-side light-permeable surface.

13. The ferrule of claim 1, wherein the at least one end-side light-permeable surface defines a normal vector oriented towards the body, such that the ferrule is passively eye safe.

14. The ferrule of claim 1, wherein the optical signals leaving the at least one end-side light- permeable surface do not propagate outside a footprint of the body.

15. The ferrule of claim 1, wherein the at least one end-side light-permeable surface defines a normal vector oriented sixty to eighty degrees relative to the longitudinal axis.

16. The ferrule of claim 1, wherein at least a portion of the at least one end-side light-permeable surface is disposed below a horizontal center plane of the body, the horizontal center plane being parallel to the longitudinal axis and perpendicular to the height dimension.

17. The ferrule of claim 16, wherein the at least one end-side light-permeable surface faces at least partially towards the horizontal center plane of the body.

18. The ferrule of claim 1, further comprising: a first pin or first pin opening defined at the end face; a second pin or second pin opening defined at the end face on an opposite side of the at least one end-side light-permeable surface from the first pin or the first pin opening; and at least a portion of the at least one end-side light-permeable surface faces towards a width axis extending between (a) the first pin or the first pin opening and (b) the second pin or the second pin opening.

19. The ferrule of claim 1, wherein the optical region comprises three or more light-turn surfaces including the at least one light-turn surface configured to reflect the optical signals from three or more corresponding optical fibers.

20. The ferrule of claim 19, wherein the three or more light-turn surfaces are internally concave within the optical region, and wherein the three or more light-turn surfaces are shaped to collimate the optical signals prior to exiting the at least one end-side light-permeable surface.21 . The ferrule of claim 1 , further comprising a top surface defining a top cutout and a bottom surface defining a bottom cutout.

22. The ferrule of claim 1, wherein the nonzero angle defines an oblique angle relative to the longitudinal axis.

23. The ferrule of claim 22, wherein the oblique angle is less than ninety degrees relative to the longitudinal axis.

24. The ferrule of claim 1, wherein the nonzero angle is parallel to a portion of the end face adjacent the at least one end-side light-permeable surface and perpendicular to the at least one end-side light-permeable surface.

25. The ferrule of claim 1, wherein the at least one fiber-side light-permeable surface defines an oblique angle relative to the height dimension of the body such that the at least one fiberside light-permeable surface is oblique from the optical signals prior to entering the at least one fiber-side light-permeable surface.

26. The ferrule of claim 1, wherein the body comprises a unitary molded structure.

27. The ferrule of claim 1, wherein the body comprises a plurality of pieces.

28. The ferrule of claim 1, wherein the body further defines at least one opening configured to receive at least two optical fibers therethrough.

29. The ferrule of claim 1, wherein the optical region is transparent.

30. The ferrule of claim 1, wherein the at least one end-side light-permeable surface is defined at a height position within the height dimension of the body.

31. The ferrule of claim 1, wherein the first side surface and the second side surface are each smooth.

32. The ferrule of claim 1, wherein the ferrule is shoulderless.

33. A connector comprising: a connector housing defining a housing opening at a front end of the connector housing; and a ferrule extending at least partly through the housing opening, the ferrule defining: a body defining: an end face; a top side and a bottom side defining a height dimension of the body therebetween with a longitudinal axis of the ferrule defined perpendicular to the height dimension, the end face defined between the top side and the bottom side, the top side and the bottom side extending rearwardly from the end face; a first side surface joining the top side and the bottom side on a first side of the body and a second side surface joining the top side and the bottom side on a second side of the body opposite the first side; and an optical region defining at least one fiber-side light-permeable surface, at least one light-turn surface, and at least one end-side light-permeable surface; the at least one end-side light-permeable surface defined along the end face; wherein the at least one light-turn surface is configured to reflect optical signals from the at least one fiber-side light-permeable surface towards the at least one end-side light- permeable surface at a nonzero angle relative to the longitudinal axis, and wherein the optical region is configured to at least partly focus the optical signals.

34. The connector of claim 33, wherein the at least one light-turn surface defines at least one lens surface, wherein the optical region is configured to at least partly focus the optical signals via the at least one lens surface.

35. The connector of claim 33, wherein the at least one end-side light-permeable surface defines at least one lens surface, wherein the optical region is configured to at least partly focus the optical signals via the at least one lens surface.

36. The connector of claim 33, wherein the connector housing is configured to overhang the end face of the body of the ferrule relative to the longitudinal axis.

37. The connector of claim 36, wherein the nonzero angle is defined such that the optical signals are configured to interact with the connector housing.

38. A connection system comprising: the connector of claim 32 and a second connector, each of the second connector comprising: a second connector housing defining a second housing opening at a front end of the second connector housing; and a second ferrule extending at least partly through the housing opening, the second ferrule defining: a second body defining: an end face; a top side and a bottom side defining a height dimension of the body therebetween with a longitudinal axis of the ferrule defined perpendicular to the height dimension, the end face defined between the top side and the bottom side, the top side and the bottom side extending rearwardly from the end face; a first side surface joining the top side and the bottom side on a first side of the body and a second side surface joining the top side and the bottom side on a second side of the body opposite the first side; and an optical region defining at least one fiber-side light-permeable surface, at least one light-turn surface, and at least one end-side light-permeable surface; the at least one end-side light-permeable surface defined along the end face;wherein the at least one light-turn surface is configured to reflect optical signals from the at least one fiber-side light-permeable surface towards the at least one endside light-permeable surface at a nonzero angle relative to the longitudinal axis, and wherein the optical region is configured to at least partly focus the optical signals; and a receptacle comprising a receptacle opening extending from a first end to a second end of the receptacle, the connector being configured to insert into the receptacle opening from the end and the second connector being configured to insert into the receptacle opening from the second end; the ferrule of the connector and the ferrule of the second connector defining an exchange zone therebetween through which the optical signals are configured to pass between the ferrule of the connector and the ferrule of the second connector.

39. A connection system comprising: a first connector and a second connector, each of the first connector and the second connector comprising: a connector housing defining a housing opening at a front end of the connector housing; and a ferrule extending at least partly through the housing opening, the ferrule defining: a body defining: an end face; a top side and a bottom side defining a height dimension of the body therebetween with a longitudinal axis of the ferrule defined perpendicular to the height dimension, the end face defined between the top side and the bottom side, the top side and the bottom side extending rearwardly from the end face; a first side surface joining the top side and the bottom side on a first side of the body and a second side surface joining the top side and the bottom side on a second side of the body opposite the first side; and an optical region defining at least one fiber-side light-permeable surface, at least one light-turn surface, and at least one end-side light-permeable surface; the at least one end-side light-permeable surface defined along the end face;wherein the at least one light-turn surface is configured to reflect optical signals from the at least one fiber-side light-permeable surface towards the at least one endside light-permeable surface at a nonzero angle relative to the longitudinal axis, and wherein the optical region is configured to at least partly focus the optical signals; and a receptacle comprising a receptacle opening extending from a first end to a second end of the receptacle, the first connector being configured to insert into the receptacle opening from the first end and the second connector being configured to insert into the receptacle opening from the second end; the ferrule of the first connector and the ferrule of the second connector defining an exchange zone therebetween through which the optical signals are configured to pass between the ferrule of the first connector and the ferrule of the second connector.

40. The system of claim 39, wherein the receptacle is configured to receive a plurality of connectors including the first connector, the second connector, and a third connector, and wherein the first connector and the third connector are configured to engage the receptacle parallel to each other and be disposed less than the height dimension away from each other when engaged with the receptacle.

41. A method of molding a ferrule, the method comprising: injecting at least one polymer into a mold, the mold comprising a plurality of surfaces configured to cause the at least one polymer to form a ferrule defining: a body defining: an end face; a top side and a bottom side defining a height dimension of the body therebetween with a longitudinal axis of the ferrule defined perpendicular to the height dimension, the end face defined between the top side and the bottom side, the top side and the bottom side extending rearwardly from the end face; a first side surface joining the top side and the bottom side on a first side of the body and a second side surface joining the top side and the bottom side on a second side of the body opposite the first side; anda transparent optical transmission region defining at least one fiber-side light-permeable surface, at least one light-turn surface, and at least one end-side light-permeable surface; the at least one end-side light-permeable surface defined along the end face; wherein the at least one light-turn surface is configured to reflect optical signals from the at least one fiber-side light-permeable surface towards the at least one end-side light-permeable surface at a nonzero angle relative to the longitudinal axis, and wherein the optical region is configured to at least partly focus the optical signals.

42. A ferrule comprising a body, the body defining: a plurality of rows of lens surfaces; a plurality of rows of fiber-side light-permeable surfaces; and a first length of the optical region of the body along the longitudinal axis between a first lens surface of a first row of lens surfaces of the plurality of rows of lens surfaces and a first fiber-side light-permeable surface of a first row of the plurality of rows of fiber-side light-permeable surfaces of the body being greater than a second length of the optical region of the body along the longitudinal axis between a second lens surface of a second row of lens surfaces of the plurality of rows of lens surfaces and a second fiber-side light-permeable surface of a second row of the plurality of rows of fiber-side light-permeable surfaces of the body.

43. A bag of parts comprising: a ferrule extending at least partly through the housing opening, the ferrule defining: a body defining: an end face; a top side and a bottom side defining a height dimension of the body therebetween with a longitudinal axis of the ferrule defined perpendicular to the height dimension, the end face defined between the top side and the bottom side, the top side and the bottom side extending rearwardly from the end face; a first side surface joining the top side and the bottom side on a first side of the body and a second side surface joining the top side and the bottom side on a second side of the body opposite the first side; andan optical region defining at least one fiber-side light-permeable surface, at least one light-turn surface, and at least one end-side light-permeable surface; the at least one end-side light-permeable surface defined along the end face; wherein the at least one light-turn surface is configured to reflect optical signals from the at least one fiber-side light-permeable surface towards the at least one end-side light-permeable surface at a nonzero angle relative to the longitudinal axis.

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