Push-pull connector for expanded-beam optical ferrules

Abstract

An optical connector configured to mate with a mating optical connector includes an optical ferrule assembly having optical waveguides attached to a first attachment area of an optical ferrule, and a cable retainer attached to the optical waveguides at a second attachment area of the optical waveguides, and a housing configured to house the optical ferrule assembly including a top housing portion configured to be removably assembled to a bottom housing portion. When the optical ferrule assembly is disposed in the bottom housing portion and the top housing portion is assembled to the bottom housing portion, a first retaining feature of the top housing portion contacts the cable retainer and holds the cable retainer in the housing at an oblique angle relative to a mating direction of the optical connector, with the optical ferrule resting on, but not secured to, one or more resting features inside the bottom housing portion.

Description

PUSH-PULL CONNECTOR FOR EXPANDED-BEAM OPTICAL FERRULESSummary

[0001] In some aspects of the present description, an optical connector configured to mate with a mating optical connector along a mating direction is provided, the optical connector including an optical ferrule assembly having one or more optical waveguides permanently attached to a first attachment area of an optical ferrule, and a cable retainer securely attached to the one or more optical waveguides at a second attachment area of the one or more optical waveguides, and a housing configured to house the optical ferrule assembly therein and including a top housing portion configured to be removably assembled to a bottom housing portion, such that when the optical ferrule assembly is disposed in the bottom housing portion and the top housing portion is assembled to the bottom housing portion, a first retaining feature of the top housing portion directly contacts the cable retainer and securely holds it in the housing at an oblique angle relative to the mating direction with the optical ferrule resting on, but not secured to, one or more resting features inside the bottom housing portion.Brief Description of the Drawings

[0002] FIG. 1 is a perspective view of an optical connector, in accordance with an embodiment of the present description;

[0003] FIGS. 2A and 2B are cutaway, perspective views of an optical connector, in accordance with an embodiment of the present description;

[0004] FIGS. 3A and 3B are side schematic views of an optical connector illustrating how it mates with an identical mating optical connector, in accordance with an embodiment of the present description;

[0005] FIGS. 4A-4C are perspective views of an optical connector illustrating alignment and resting features, in accordance with an embodiment of the present description; and

[0006] FIGS. 5A and 5B are perspective views of an assembled optical connector, including an outer sleeve configured to hold the assembly together, in accordance with an embodiment of the present description.Detailed Description

[0007] In the following description, reference is made to the accompanying drawings that form a part hereof and in which various embodiments are shown by way of illustration. The drawings are not necessarily to scale. It is to be understood that other embodiments are contemplated and may be made without departing from the scope or spirit of the present description. The following detailed description, therefore, is not to be taken in a limiting sense.

[0008] Fiber optic technology has become the backbone of modern communication systems, providing high-speed data transmission over long distances. Traditional connector technology, known as physical contact technology, involves fibers where the ends of the fibers are polished. These polished fibers are then brought into physical contact with each other to establish an optical connection. This physical contact must be precise, as it requires the glass of the fibers to be slightly compressed to ensure optimal optical contact.

[0009] However, this traditional approach has several drawbacks. The requirement for physical contact between the fibers makes the connection highly sensitive to dust and debris, which can disrupt the signal if the fiber faces are not perfectly clean. Additionally, the alignment of the fibers must be exact, which can be challenging to achieve and maintain, especially in environments where connectors are frequently mated and de-mated.

[0010] The industry has attempted to address some of these issues by introducing expanded beam concepts, in which optical fibers are held in matching and precisely mating optical ferrules, where the sensitivity to dust and debris is reduced. These optical ferrules also allow for the expansion of the number and density of optical fibers in the connectors, and may contain 8, 12, 16, or any higher number of optical fibers in a reliable connection.

[0011] It would be ideal to employ these expanded beam optical ferrules (with a relatively high number of optical fibers) in a push-pull format connector that fits within an existing standard patch panel. According to some aspects of the present description, an optical connector assembly combines the improved performance and fiber density of expanded beam optical ferrules with an industry standard connector design that fits into a standard patch panel. An optical connector with novel features for creating expanded beam ferrule connections within an existing housing form factor is described herein.

[0012] According to some aspects of the present description, an optical connector configured to mate with a mating optical connector along a mating direction may include an optical ferrule assembly and a housing configured to house the optical ferrule assembly therein. In some embodiments, the optical ferrule assembly may include one or more optical waveguides (e.g., optical fibers) permanently attached to a first attachment area (e.g., an input surface) of an optical ferrule, and a cable retainer securely attached to the one or more optical waveguides at a second attachment area of the one or more optical waveguides (e.g., a point along the length of the optical waveguides and separated from the first attachment area by a predetermined distance).

[0013] In some embodiments, the housing may include a top housing portion (e.g., a cover portion) configured to be removably assembled to a bottom housing portion. In some embodiments, when the optical ferrule assembly is disposed in the bottom housing portion and the top housing portion is assembled to the bottom housing portion, a first retaining feature (e.g., a ramp or inclined surface) in the top housing portion directly contacts the cable retainer and securely holds the cable retainer in the housing at an oblique angle (e.g., about 5 degrees, or about 10 degrees, or about 15degrees, or about 20 degrees) relative to the mating direction. In some embodiments, the optical ferrule may rest on, but not be secured to, one or more resting features (e.g., small block features which support the resting optical ferrule when not mated) inside the bottom housing portion. In some embodiments, when the optical connector mates with a mating optical connector, the optical ferrule may leave the one or more resting features (i.e., the act of mating may push the optical ferrule up and away from the resting features). In some such embodiments, the one or more optical waveguides may bend, or may bend more, between the first and second attachments areas, and the optical ferrule may optically couple to a mating optical ferrule of the mating optical connector.

[0014] In some embodiments, the bottom housing portion may further include a platform feature (or “platform”) that is configured to hold the cable retainer in place from below. In some embodiments, the platform feature may be, for example, a pocket having a surface which directly contacts a bottom surface of the cable retainer and holds it at the oblique angle. In some embodiments, when assembled, the cable retainer may rest on the platform and may be secured between the first retaining feature in the top housing portion and the platform feature. In some embodiments, at least one of the top housing portion and the bottom housing portion may further include one or more latching features configured to removably assemble the top housing portion to the bottom housing portion.

[0015] In some embodiments, the optical connector may further include a sleeve configured to surround the top housing portion and bottom housing portion and secure them as an assembly. In some such embodiments, the top housing portion may have a first alignment feature (e.g., a projection) on a first external surface of the top housing portion, and the bottom housing portion may have a second alignment feature (e.g., a second projection) on a first external surface of the bottom housing portion. In some embodiments, the first external surface of the top housing portion may face away from the first external surface of the bottom housing portion.

[0016] In some such embodiments, the sleeve may have a first channel or groove on a first inner surface of the sleeve, and a second channel or groove on an opposing, second inner surface of the sleeve. The first channel and second channel may each be disposed such that they correspond to a location of either the first alignment feature or the second alignment feature on the optical connector housing assembly.

[0017] In some embodiments, the location of the first alignment feature on the first external surface of the top housing portion may be offset in a lateral direction orthogonal to a mating direction of the optical connector in a first offset direction and by a first distance dl from a center line of the optical connector. In some embodiments, the location of the second alignment feature on the first external surface of the bottom housing portion may be offset in a lateral direction orthogonal to a mating direction of the optical connector in a second offset direction, opposite the first offset direction, and by a second distance d2 from a center line of the optical connector. In some embodiments, the first distance, dl, and the second distance, d2, may be configured such that the firstchannel of the sleeve may be aligned with either the first alignment feature or the second alignment feature (i.e., in some embodiments, the sleeve and the grooves therein may be arranged symmetrically such that the orientation of the sleeve relative to the optical connector may be reversed while still enabling the locations of the channels to correspond to the locations of both alignment features).

[0018] In some embodiments, one or both of the first alignment feature and the second alignment features may be or include inclined surfaces (e.g., ramps which may enable the sleeve to be assembled to the optical connector at least in a first assembly direction). In some embodiments, at least one of the first alignment feature and the second alignment feature may include a split ramp structure.

[0019] In some embodiments, the optical connector may be a hermaphroditic connector (i.e., may be used as either the first or second optical connectors in the mating pair of optical connectors). In some embodiments, the optical connector and the mating optical connector may be identical connectors.

[0020] Turning now to the figures, FIG. 1 is a perspective view of an embodiment of an optical connector, according to the present description. In some embodiments, optical connector 300 may include an optical ferrule assembly 200 and a housing 100. In some embodiments, optical ferrule assembly 200 may include one or more optical waveguides 30 (e.g., one or more optical fibers), an optical ferrule 10, and a cable retainer 20. In some embodiments, the optical waveguides 30 may be permanently attached to a first attachment area 15 of optical ferrule 10. In some embodiments, cable retainer 20 may be securely attached to optical waveguides 30 at a second attachment area 25 of optical waveguides 30. In some embodiments, the distance between the first attachment area 15 and second attachment area 25 may be such that the optical waveguides 30 are allowed to bend between the first 15 and second 25 attachment areas, allowing the optical waveguides 30 to provide a predetermined mating force between optical ferrule 10 and a mating optical ferrule of a mating optical connector when fully mated.

[0021] In some embodiments, housing 100 may be configured to house optical ferrule assembly 200 therein and may include top housing portion 100a configured to be removably assembled to a bottom housing portion 100b. In some embodiments, when optical ferrule assembly 200 is disposed in bottom housing portion 100b and top housing portion 100a is assembled to bottom housing portion 100b, a first retaining feature 105 (see, e.g., first retaining feature 105 of FIG. 2B) of top housing portion 100a may directly contact cable retainer 20 and securely hold cable retainer 20 in housing 100 at an oblique angle relative to the mating direction (see, e.g., angle 9 and mating direction 70 as shown in FIG. 3B) with optical ferrule 10 resting on, but not secured to, one or more resting features 17 inside bottom housing portion 100b.

[0022] In some embodiments, top housing portion 100a may include latching features 112 to removably assemble the top housing portion 100a to the bottom housing portion 100b. In some other embodiment, bottom housing portion 100b may include the latching features 112 rather than top housing portion 100a. In some embodiments, both top housing portion 100a and bottom housingportion 100b may include one or more corresponding latching features (e.g., corresponding latches and recesses) to hold the portions 100a and 100b in an assembled state.

[0023] In some embodiments, optical connector 300 may further include a sleeve 40 which may be disposed around optical connector 100 when it is fully assembled. In such embodiments, sleeve 40 may act to prevent an unwanted disassembly of the top 100a and bottom 100b housing portions.

[0024] FIGS. 2A and 2B are cutaway, perspective views of an embodiment of an optical connector 300, including internal details of connector housing 100, according to the present description. FIGS. 2A and 2B may be examined together for the following discussion. It should be noted that FIGS. 2A and 2B show optical connector 300 in two opposing orientations, with top housing portion on top and bottom housing portion on top, respectively, for additional clarity.

[0025] Each figure shows a length of optical waveguides 30 held between a first attachment area 15 (located on optical ferrule 10) and a second attachment 25 (located on the optical waveguides 30 at a location of a cable retainer 20). The first attachment area 15 and second attachment area 25 are separated by a distance such that optical waveguides 30 are allowed to flex or bend to create a predetermined mating force that holds optical ferrule 10 in a mated position to a mating optical ferrule. This bending of optical waveguides 30 may in some embodiments be enabled by the relative positions and orientations of cable retainer 20 and optical ferrule 10, which are determined by features within top housing portion 100a and bottom housing portion 100b of housing 100.

[0026] For example, in some embodiments, optical ferrule 10 may rest on resting features 17 in bottom housing portion 100b, such that optical ferrule 10 is held at an oblique angle to a mating direction of optical connector 300. As another example, in some embodiments, cable retainer 10 may be held at an oblique angle to the mating direction of the optical connector 300 by being disposed between a first retaining feature 105 (see FIG. 2B) in top housing portion 100a and a platform 110 in bottom housing portion 100b.

[0027] FIGS. 3A and 3B are side schematic views of an embodiment of an optical connector illustrating how it mates with an embodiment of an identical mating optical connector, according to the present description. FIG. 3 A shows a housing 100-1 of a single optical connector 300, and FIG. 3B shows a schematic of a first optical connector 300-1 mating with a second, identical optical connector 300-2. Both FIGS. 3A and 3B may be examined together for the following discussion.

[0028] Looking first at FIG. 3A, optical connector 300 includes a cable retainer 20a held at an oblique angle 9 relative to a mating direction 70 of optical connector 300, disposed between first retaining feature 105a and platform 110a. One or more optical waveguides 30a are extend between cable retainer 20a and optical ferrule 10a. Optical ferrule 10a rests on one or more resting features 17a, such that optical waveguides are allowed to bend or flex between cable retainer 20a and optical ferrule 10a.

[0029] Turning to FIG. 3B, optical connectors 300-1 and 300-2 (which may, in some embodiments, be separate instances of optical connector 300 of FIG. 3 A or any of the opticalconnectors described herein) are shown in a mated position. In the mated position, optical ferrule 10a (and corresponding optical ferrule 10b) may leave (rise away from) resting position 50 on resting features 17a (and resting features 17b) into non-resting position 51, allowing optical waveguides 30a (and optical waveguides 30b) to bend, or to bend more than their original amount of bend. That is, optical ferrules 10a and 10b are not permanently attached to corresponding resting features 17a and 17b, but only rest on these features at location 50 such that the optical ferrules 10a and 10b are at an angle conducive to mating when pressed or brought together along mating direction 70.

[0030] FIGS. 4A-4C are perspective views of an optical connector 300 illustrating embodiments of alignment and resting features, according to of the present description. FIG. 4A shows an end view of housing 100 including top housing portion 100a and bottom housing portion 100b in a fully assembled position. FIG. 4A additionally provides a clearer view of an embodiment of resting features 17 and optical ferrule 10 resting on these features. In some embodiments, top housing portion 100a may have a first alignment feature 120 (e.g., a projection or keying feature) on a first external surface 111 of top housing portion 100a, and the bottom housing portion 100b may have a second alignment feature 130 (e.g., a second projection or keying feature) on a first external surface 121 of bottom housing portion 100b. In some embodiments, first external surface 111 of top housing portion 100a may face away from first external surface 121 of bottom housing portion 100b.

[0031] In some embodiments, first alignment feature 120 and second alignment feature 130 may be or include inclined surfaces (e.g., ramped edges) to facilitate positioning of the sleeve (e.g., sleeve 40 as described elsewhere herein) during assembly (see, for example, ramp feature 120 in FIG. 4A and 130 in FIG. 4B). In some embodiments, at least one of first alignment feature 120 and second alignment feature 130 may be a split ramp (see, e.g., feature 120 in FIG. 4B).

[0032] Finally, FIGS. 5 A and 5B are perspective views of an embodiment of an assembled optical connector, including an outer sleeve 40 configured to hold the assembly together, according to the present description.

[0033] Looking at FIG. 5A, the location of first alignment feature 120 on first external surface 111 of top housing portion 100a may be offset in a lateral direction orthogonal to a mating direction of optical connector 300 in a first offset direction 62 and by a first distance d 1 from a center line 60 of optical connector 300, and the location of second alignment feature 130 on first external surface 121 of bottom housing portion 100b may be offset in a lateral direction orthogonal to a mating direction of optical connector 300 in a second offset direction 64 and by a second distance d2 from a center line of the optical connector. In some embodiments, first offset direction 62 may be opposite second offset direction 64.

[0034] Turning to FIG. 5B, and in some embodiments, sleeve 40 may have a first channel 42 on a first inner surface 41 of the sleeve and a second channel 44 on an opposing, second inner surface 43 of the sleeve. In some embodiments, first channel 42 and second channel 44 may each be disposed such that they correspond to a location of either first alignment feature 120 or second alignmentfeature 130. Stated another way, in one orientation, first channel 42 may be co-located with first alignment feature 120, and second channel 44 may be co-located with second alignment feature 130, while in another, opposite orientation, first channel 42 may be co-located with second alignment feature 130, and second channel 44 may be co-located with first alignment feature 120.

[0035] In some embodiments, first distance dl and second distance d2 are such that first channel 42 of sleeve 40 may be aligned with either first alignment feature 120 or second alignment feature 130 (i.e., sleeve 40 may have bilateral symmetry around center line 60 such that sleeve 40 may be oriented in either of two opposing orientations and still be aligned with first 120 and second 130 alignment features).

[0036] Terms such as “about” will be understood in the context in which they are used and described in the present description by one of ordinary skill in the art. If the use of “about” as applied to quantities expressing feature sizes, amounts, and physical properties is not otherwise clear to one of ordinary skill in the art in the context in which it is used and described in the present description, “about” will be understood to mean within 10 percent of the specified value. A quantity given as about a specified value can be precisely the specified value. For example, if it is not otherwise clear to one of ordinary skill in the art in the context in which it is used and described in the present description, a quantity having a value of about 1, means that the quantity has a value between 0.9 and 1.1, and that the value could be 1.

[0037] Terms such as “substantially” will be understood in the context in which they are used and described in the present description by one of ordinary skill in the art. If the use of “substantially equal” is not otherwise clear to one of ordinary skill in the art in the context in which it is used and described in the present description, “substantially equal” will mean about equal where about is as described above. If the use of “substantially parallel” is not otherwise clear to one of ordinary skill in the art in the context in which it is used and described in the present description, “substantially parallel” will mean within 30 degrees of parallel. Directions or surfaces described as substantially parallel to one another may, in some embodiments, be within 20 degrees, or within 10 degrees of parallel, or may be parallel or nominally parallel. If the use of “substantially aligned” is not otherwise clear to one of ordinary skill in the art in the context in which it is used and described in the present description, “substantially aligned” will mean aligned to within 20% of a width of the objects being aligned. Objects described as substantially aligned may, in some embodiments, be aligned to within 10% or to within 5% of a width of the objects being aligned.

[0038] All references, patents, and patent applications referenced in the foregoing are hereby incorporated herein by reference in their entirety in a consistent manner. In the event of inconsistencies or contradictions between portions of the incorporated references and this application, the information in the preceding description shall control.

[0039] Descriptions for elements in figures should be understood to apply equally to corresponding elements in other figures, unless indicated otherwise. Although specific embodimentshave been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and / or equivalent implementations can be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this disclosure be limited only by the claims and the equivalents thereof.

Claims

What is claimed:

1. An optical connector configured to mate with a mating optical connector along a mating direction and comprising: an optical ferrule assembly comprising one or more optical waveguides permanently attached to a first attachment area of an optical ferrule, and a cable retainer securely attached to the one or more optical waveguides at a second attachment area of the one or more optical waveguides; and a housing configured to house the optical ferrule assembly therein and comprising a top housing portion configured to be removably assembled to a bottom housing portion, such that when the optical ferrule assembly is disposed in the bottom housing portion and the top housing portion is assembled to the bottom housing portion, a first retaining feature of the top housing portion directly contacts the cable retainer and securely holds the cable retainer in the housing at an oblique angle relative to the mating direction with the optical ferrule resting on, but not secured to, one or more resting features inside the bottom housing portion.

2. The optical connector of claim 1, wherein, when the optical connector mates with a mating optical connector, the optical ferrule leaves the one or more resting features, the one or more optical waveguides bend, or bend more, between the first and second attachments areas, and the optical ferrule optically couples to a mating optical ferrule of the mating optical connector.

3. The optical connector of claim 1, wherein the bottom housing portion further comprises a platform configured to hold the cable retainer in place, wherein, when assembled, the cable retainer rests on the platform and is secured between the first retaining feature and the platform.

4. The optical connector of claim 1 , wherein at least one of the top housing portion and the bottom housing portion has one or more latching features configured to removably assemble the top housing portion to the bottom housing portion.

5. The optical connector of claim 1, further comprising a sleeve configured to surround the top housing portion and bottom housing portion and secure them as an assembly.

6. The optical connector of claim 5, wherein the top housing portion has a first alignment feature on a first external surface of the top housing portion and the bottom housing portion has a second alignment feature on a first external surface of the bottom housing portion, wherein the first external surface of the top housing portion faces away from the first external surface of the bottom housing portion.

7. The optical connector of claim 6, wherein the sleeve has a first channel on a first inner surface of the sleeve and a second channel on an opposing, second inner surface of the sleeve, the first channel and second channel each disposed such that they correspond to a location of either the first alignment feature or the second alignment feature.

8. The optical connector of claim 7, wherein the location of the first alignment feature on the first external surface of the top housing portion is offset in a lateral direction orthogonal to a mating direction of the optical connector in a first offset direction and by a first distance dl from a center line of the optical connector, and the location of the second alignment feature on the first external surface of the bottom housing portion is offset in a lateral direction orthogonal to a mating direction of the optical connector in a second offset direction and by a second distance d2 from a center line of the optical connector, wherein the first offset direction is opposite the second offset direction, and the first distance and the second distance are such that the first channel of the sleeve may be aligned with either the first alignment feature or the second alignment feature.

9. The optical connector of claim 6, wherein the first alignment feature and second alignment features comprise inclined surfaces.

10. The optical connector of claim 9, wherein at least one of the first alignment feature and the second alignment feature comprises a split ramp.

11. The optical connector of claim 1, wherein the optical connector is hermaphroditic.

12. The optical connector of claim 1, wherein the optical connector and the mating optical connector are identical connectors.

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