Reduced SC-connector

Abstract

An optical fiber connector introducing a redesigned inner housing that replaces the conventional, expensive ferrule assembly with a simpler, unitary, single-piece inner housing body. The inner housing defines a ferrule receiving socket and an optical fiber conduit extending along a longitudinal centerline axis, with a first end and a second end. The inner housing can be molded over a ferrule, with a free end of the ferrule extending beyond the second end of the inner housing. The connector further includes a sliding outer housing disposed over the inner housing, comprising an elongated body with a longitudinal bore extending between a first end and an opposite second end, the second end being configured to mate with a coupling housing.

Description

Attorney Docket No. 02316.8916WOU1 / 7487REDUCED SC-CONNECTORCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 696,530, filed September 19, 2024, titled “REDUCED SC-CONNECTOR,” the disclosure of which is hereby incorporated herein by reference.TECHNICAL FIELD

[0001] The present disclosure relates generally to fiber optic cable connectors, and more particularly to a fiber optic connector assembly that reduces manufacturing costs and complexity by using an inner housing structure, eliminating the need for traditional spring-biased ferrule assemblies.BACKGROUND

[0002] Optical fiber connectors are essential components in optical fiber communication systems. These connectors serve to join lengths of optical fiber to create extended runs or to connect optical fibers to active components. An optical fiber connector must generally couple or join two optical fibers with minimal insertion loss, and provide mechanical stability and protection to the junction between the optical fibers within the operating environment. Achieving low insertion loss is primarily dependent on the precise alignment of the fiber ends, the width of the gap between the ends, and the optical surface condition of the ends. Stability and protection at the junction are generally functions of the connector design, such as minimizing the effects of differential thermal expansion.

[0003] One commonly used optical fiber connector is the SC connector, which includes an optical fiber terminating a ferrule projecting from a barrel. The ferrule assembly is housed within an inner housing, allowing the ferrule to project from one end of the inner housing. The inner housing is oriented relative to a sleeve or outer housing into which it snap-locks. One connector is inserted into one end of a coupler housing or adapter, and another connector is inserted into the other end, facilitating the alignment of the ferrule ends for optical connection.

[0004] These connectors enable the joining of optical fibers end-to-end, ensure proper alignment of fiber cores, and facilitate the transfer of optical signals with minimal insertion loss and return loss. Examples of such fiber optic connectors include those disclosed in U.S. Pat. Nos. 5,212,752; 5,317,663; 5,809,192; 6,206,581; 6,293,710; 10,545,297; 11,169,332; and W02020 / 237085. Although these connectors work well for their intended purpose, further improvements are desired.SUMMARY

[0005] The present disclosure relates to optical fiber connectors and specifically addresses the need to reduce material and manufacturing costs while maintaining or improving performance. Traditional optical fiber connectors typically include multiple components, such as a ferrule assembly and a compression spring, which contribute significantly to the overall cost of production. The embodiments disclosed herein introduce a redesigned inner housing that eliminates the need for these costly components.

[0006] In the first embodiment, an optical fiber connector is presented with a unitary, single-piece inner housing configured to receive a ferrule. For example, the inner housing can be overmolded onto the ferrule, or the ferrule can be press fit to achieve a friction fit within the inner housing. This design eliminates the need for a compression spring, reducing complexity and cost. The inner housing is slidably positioned within a sliding outer housing, which allows for connection to a coupling housing.

[0007] The second embodiment further refines the design by incorporating an adjustable inner housing that compensates for misalignments caused by eccentricities in the fiber cores. This tuning capability allows for the fine-tuning of the fiber alignment during assembly, further improving the performance of the optical connection while maintaining a lower cost structure.

[0008] The third embodiment presents an optical fiber connector that omits the sliding outer housing altogether. Instead, the inner housing is directly coupled to a coupling housing. This design simplifies the assembly process and reduces costs while still ensuring reliable fiber connections. The inner housing in this embodiment is equipped with latch projections that engage with corresponding latch members in the coupling housing, allowing for secure coupling and easy release by rotating the connector.

[0009] Overall, the disclosed embodiments provide cost-effective solutions for manufacturing optical fiber connectors without compromising the performance or reliability of the connections. These innovations are intended to address the growing demand for more affordable and efficient fiber optic components in the telecommunications industry.

[0010] A variety of additional inventive aspects will be set forth in the description that follows. The inventive aspects can relate to individual features and to combinations of features. It is to be understood that both the forgoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive concepts upon which the embodiments disclosed herein are based.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The accompanying drawings, which are incorporated in and constitute a part of the description, illustrate several aspects of the present disclosure. A brief description of the drawings is as follows:

[0012] FIG. 1 is an exploded, perspective view illustrating an optical fiber connector, in accordance with a first embodiment of the disclosure.

[0013] FIG. 2 is a perspective view illustrating the optical fiber connector shown in FIG. 1.

[0014] FIG. 3 is a cross-sectional view illustrating the optical fiber connector shown in FIG. 2.

[0015] FIG. 4 is a perspective view of the optical fiber connector depicted in FIG. 1, rotated approximately 90° about its longitudinal centerline axis from the orientation shown in FIG. 2.

[0016] FIG. 5 is a cross-sectional view illustrating the optical fiber connector as shown in FIG. 4.

[0017] FIG. 6 is a perspective view of a ferrule and inner housing, in accordance with the first embodiment of the disclosure.

[0018] FIG. 7 is an alternate perspective view of the ferrule and inner housing depicted in FIG. 6.

[0019] FIG. 8 is an exploded, perspective cross-sectional view illustrating the ferrule and inner housing of FIG. 6.

[0020] FIG. 9 is a perspective cross-sectional view illustrating the ferrule and inner housing of FIG. 6 in an assembled form.

[0021] FIG. 10 is an exploded, perspective cross-sectional view illustrating an optical fiber connector in accordance with the first embodiment of the disclosure.

[0022] FIG. 11 is a perspective view of the optical fiber connector of FIG. 10 in an assembled form.

[0023] FIG. 12 is a close-up, cross-sectional view of the ferrule and inner housing, in accordance with the first embodiment of the disclosure.

[0024] FIG. 13 is a perspective view illustrating an optical fiber connector with the inner housing inserted into a sliding outer housing in accordance with the first embodiment of the disclosure.

[0025] FIG. 14 is a perspective view illustrating the optical fiber connector of FIG.13 with the sliding outer housing in a forward position relative to the inner housing.

[0026] FIG. 15 is a perspective view illustrating the optical fiber connector of FIG.14 with the sliding outer housing in an aft position relative to the inner housing.

[0027] FIG. 16 is a perspective view illustrating the connection between an optical fiber connector of the first embodiment and a coupling housing.

[0028] FIG. 17 is an exploded, perspective view illustrating an optical fiber connector, in accordance with a second embodiment of the disclosure.

[0029] FIG. 18 is a perspective view illustrating the optical fiber connector shown in FIG. 17.

[0030] FIG. 19 is a cross-sectional view illustrating the optical fiber connector shown in FIG. 18.

[0031] FIG. 20 is a perspective view of the optical fiber connector depicted in FIG.17, rotated approximately 90° about its longitudinal centerline axis from the orientation shown in FIG. 18.

[0032] FIG. 21 is a cross-sectional view illustrating the optical fiber connector as shown in FIG. 20.

[0033] FIG. 22 is a perspective view of a ferrule and inner housing, in accordance with the second embodiment of the disclosure.

[0034] FIG. 23 is an alternate perspective view of the ferrule and inner housing depicted in FIG. 22.

[0035] FIG. 24 is an exploded, perspective cross-sectional view illustrating the ferrule and inner housing of FIG. 22.

[0036] FIG. 25 is a perspective cross-sectional view illustrating the ferrule and inner housing of FIG. 24 in an assembled form.

[0037] FIG. 26 is a close-up, cross-sectional view of the ferrule and inner housing, in accordance with the second embodiment of the disclosure.

[0038] FIG. 27 is a perspective view of the optical fiber connector depicted in FIG.26, rotated approximately 90° about its longitudinal centerline axis from the orientation shown in FIG. 26.

[0039] FIG. 28 is a cross-sectional view illustrating the ferrule and inner housing shown in FIG. 25.

[0040] FIG. 29 is a perspective view illustrating an optical fiber connector with the inner housing inserted into a sliding outer housing in accordance with the second embodiment of the disclosure.

[0041] FIG. 30 is a perspective view of the optical fiber connector with the inner housing inserted into the sliding outer housing depicted in FIG. 29, with the rotated inner housing approximately 90° about its longitudinal centerline axis from the orientation shown in FIG. 29.

[0042] FIG. 31 is a perspective view illustrating the optical fiber connector of FIG. 30 with the sliding outer housing in a forward position relative to the inner housing.

[0043] FIG. 32 is a perspective view illustrating the optical fiber connector of FIG. 30 with the sliding outer housing in an aft position relative to the inner housing.

[0044] FIG. 33 is a perspective view illustrating the connection between an optical fiber connector of the second embodiment and a coupling housing.

[0045] FIG. 34 is an exploded, perspective view illustrating an optical fiber connector, in accordance with a third embodiment of the disclosure.

[0046] FIG. 35 is a perspective view illustrating the optical fiber connector shown in FIG. 34.

[0047] FIG. 36 is a cross-sectional view illustrating the optical fiber connector shown in FIG. 35.

[0048] FIG. 37 is a perspective view of the optical fiber connector depicted in FIG. 17, rotated approximately 90° about its longitudinal centerline axis from the orientation shown in FIG. 35.

[0049] FIG. 38 is a cross-sectional view illustrating the optical fiber connector as shown in FIG. 37.

[0050] FIG. 39 is a perspective view of a ferrule and inner housing, in accordance with the third embodiment of the disclosure.

[0051] FIG. 40 is an alternate perspective view of the ferrule and inner housing depicted in FIG. 39.

[0052] FIG. 41 is an exploded, perspective cross-sectional view illustrating the ferrule and inner housing of FIG. 40.

[0053] FIG. 42 is a perspective cross-sectional view illustrating the ferrule and inner housing of FIG. 41 in an assembled form.

[0054] FIG. 43 is an exploded, perspective cross-sectional view illustrating an optical fiber connector in accordance with the third embodiment of the disclosure.

[0055] FIG. 44 is a close-up, cross-sectional view of an optical fiber connector in accordance with the third embodiment of the disclosure.

[0056] FIG. 45 is a perspective view illustrating the connection between an optical fiber connector of the third embodiment and a coupling housing.

[0057] FIG. 46 is an exploded, perspective view illustrating a conventional optical fiber connector.

[0058] FIG. 47 is a perspective view illustrating the optical fiber connector shown in FIG. 46.

[0059] FIG. 48 is a perspective view illustrating the connection between the optical fiber connector shown in FIG. 46 and a coupling housing.DETAILED DESCRIPTION

[0060] Embodiments of the present disclosure are directed towards reducing the material costs associated with the production of optical fiber connectors while minimizing any adverse effects on production labor and the utilization of existing assembly equipment. These embodiments achieve cost efficiency by simplifying the design of the connector, including through innovations in the construction of the inner housing and ferrule assembly.

[0061] Referring to FIGS. 46-48, a conventional optical fiber connector 10 is depicted. The typical components of such a connector, which can take the form of an SC- compatible connector, include a ferrule assembly 11. The ferrule assembly 11 typically includes a ferrule 15, which is positioned within a cavity collectively defined by an inner housing 40 and a rear body 25. The ferrule 15 is forwardly biased within the cavity by a compression spring 20. Thereafter, the inner housing 40 is positioned within a sliding outer housing 50, which permits connection to an adapter or coupling housing 95.

[0062] Each component of the optical fiber connector 10 contributes to the overall material cost of the connector. Among these, the ferrule 15 is typically the most expensive. In conventional designs, the ferrule 15 is often overmolded with a first retention member or hub 18, which is configured to engage with the compression spring 20, thereby providing the necessary forward bias. Additionally, the first retention member 18 typically engages either the rear body 25 or the inner housing 40 to inhibit rotation within the ferrule assembly 11.

[0063] The ferrule 15 alone can account for approximately 55% of the total cost of a conventional optical fiber connector. The compression spring 20 and the rear body 25 also represent significant cost factors in conventional optical fiber connectors, together contributing approximately 25% to the overall cost. The sliding outer housing 50, which ensures the proper connection of the optical fiber connector 10 to a coupling housing 95, can contribute up to an additional 15% of the total cost.

[0064] Despite the associated expense, these costly components are generally deemed necessary in conventional designs to achieve the desired performance characteristics. In the context of a coupling housing 95 receiving two optical fiber connectors 10, the spring biasing mechanism plays an important role. The spring biases the ferrules together, ensuring that the fiber ends remain in continuous and secure contact when two fiber-optic cables are connected. This biasing mechanism provided by the ferrule assembly 11 compensates for any slight misalignments or variations in ferrule position or ferrule length, thereby minimizing insertion loss and ensuring reliable signal transmission.

[0065] While a full connection typically involves the use of two optical fiber connectors, only one of these connectors needs to be equipped with a compression spring to achieve the necessary biasing. Embodiments of the present disclosure introduce an optical fiber connector with a redesigned inner housing that replaces the conventional, expensive housing and ferrule assembly with a simpler, unitary, single-piece inner housing body. This redesigned housing is configured to receive a ferrule, thereby significantly reducing the material and manufacturing costs.

[0066] First Embodiment

[0067] Referring to FIGS. 1-5, an optical fiber connector 100 is depicted in accordance with a first embodiment of the disclosure. The optical fiber connector 100 includes an inner housing 111 configured to receive a ferrule 115. The inner housing 111can be slidably positioned within a sliding outer housing 150. In certain embodiments, a crimp eyelet 112 and a cable boot 113 can optionally be coupled to a first end 123 of the inner housing 111. Additionally, a dust cap 155 can be optionally positioned over an exposed end of the ferrule 115. In other embodiments, any of the crimp eyelet 112, cable boot 113, and dust cap 155 can be omitted.

[0068] Embodiments of the present disclosure provide a springless optical fiber connector 100, wherein the traditionally multi-component compression spring assembly can be replaced with a unitary, single-piece inner housing 111 configured to receive a ferrule 115. For example, the inner housing 111 can be overmolded onto the ferrule 115, or alternatively, the ferrule 115 can be press fit to achieve a friction fit within the inner housing 111. This design presents a lower-cost optical fiber connector 100 that remains compatible with any spring-biased connector to complete an optical connection.

[0069] With additional reference to FIGS. 6-9, the ferrule 115 can be defined by a substantially cylindrical body 116 extending along a longitudinal centerline axis. The ferrule 115 can be composed of a ceramic material, or similar material, and can include an optical fiber receiving passageway 117 formed along the longitudinal centerline axis (as depicted in FIG. 8). In some embodiments, the optical fiber receiving passageway 117 can feature a larger diameter, funnel-shaped opening configured to receive an optical fiber 122 along with its coating. An adhesive can be introduced into the optical fiber receiving passageway 117 to secure the optical fiber in the desired position. Alternatively, the optical fiber can be mechanically attached to the ferrule 115.

[0070] Although the ferrule 115 is depicted as having a conical tip with a beveled end portion 118 terminating in a polished end face 114, other embodiments may employ a flat or stepped ferrule tip. The design of the ferrule can be configured to facilitate the insertion of the ferrule 115 into an alignment sleeve 97.

[0071] In some embodiments, the inner housing 111 can be overmolded onto the ferrule 115 to create a secure connection. In such embodiments, a notch 119 may be defined along the body of the ferrule 115, positioned transversely to the longitudinal centerline axis, for example, near the end opposite the end portion 118. The notch 119 can serve as a mechanical anchor during the overmolding process, ensuring that the ferrule 115 is securely held within the inner housing 111.

[0072] In embodiments where the ferrule 115 is press fit into the inner housing 111, the inner housing 111 can define a ferrule receiving socket 120, which is shaped and sized to accommodate the substantially cylindrical body of the ferrule 115.

[0073] A retaining ridge 121 can be defined within the ferrule receiving socket 120 and can be configured to engage with the notch 119 defined by the ferrule 115, and can serve to secure the ferrule 115 within the ferrule receiving socket 120 both axially along the longitudinal centerline axis and rotationally about the longitudinal centerline axis.

[0074] The ferrule 115 extends in a cantilevered manner from the ferrule receiving socket 120 within a shroud 127 defined by the inner housing 111, with the end portion 118 of the ferrule 115 extending slightly beyond a second end 124 of the inner housing 111 (as depicted in FIG. 9). As further depicted in FIG. 10, in some embodiments, a dust cap 155 can be positioned over the end portion 118 of the ferrule 115 to protect the polished end face 114 of the ferrule 115.

[0075] To facilitate the passage of the optical fiber, the inner housing 111 can further define an optical fiber conduit 126, which can extend from the ferrule receiving socket 120 to the first end 123 of the inner housing 111. In some embodiments, the optical fiber conduit 126 can be tapered along the longitudinal centerline axis, featuring a smaller diameter portion 128 in proximity to the ferrule receiving socket 120 and a relatively larger diameter portion 129 in proximity to the first end 123. This tapering of the optical fiber conduit 126 generally facilitates the positioning and assembly of the optical fiber 122 and ferrule 115 within the inner housing 111, by enabling some movement of the optical fiber within the optical fiber conduit 126 while directing adhesive applied at the first end 123 towards the ferrule 115.

[0076] With continued reference to FIG. 10, in some embodiments, the first end 123 of the inner housing 111 can define a crimp surface 131, which can be substantially cylindrical in shape and centered about the longitudinal centerline axis. Additionally, in some embodiments, the crimp surface 131 can include a plurality of laterally extending ribs 132, designed to ensure a secure fit between the crimp surface 131 and the crimp eyelet 112, which can be positioned around the crimp surface 131. As further depicted in FIGS. 10-11, the cable boot 113 can optionally be positioned over the first end 123 of the inner housing 111, thereby shielding and securing the crimp surface 131 and crimp eyelet 112. In alternative embodiments, either the crimp eyelet 112 or the cable boot 113, or both, can be omitted.

[0077] In some embodiments, the exterior of the inner housing 111 can generally have a quadrilateral cross-sectional shape, transverse to the longitudinal centerline axis, and can define one or more chamfered comers 135, which can provide a rotational orientation reference for the proper alignment of the inner housing 111 within the slidingouter housing 150, as well as for the positioning of the optical fiber connector 100 within a coupling housing 95.

[0078] As depicted in FIG. 11 , one or more lateral exterior sides of the inner housing 111 can define a first latch projection 133 and a second latch projection 134. For instance, in certain embodiments, the inner housing 111 can define a pair of first latch projections 133 and a pair of second latch projections 134, for example, positioned on opposing exterior lateral sides of the inner housing 111.

[0079] As depicted in FIG. 12, the first latch projections 133 can extend laterally outward from the longitudinal centerline axis by a first distance DI, while the second latch projections 134 can extend laterally outward by a second distance D2, where D2 is greater than DI. Consequently, the second latch projections 134 generally extend further from the longitudinal centerline axis than the first latch projections 133. Additionally, the second latch projections 134 can include a stop surface 136 and a ramp surface 137, which can be configured to ease assembly and facilitate sliding operation with the sliding outer housing 150. Furthermore, in some embodiments, both the first latch projections 133 and the second latch projections 134 can be formed on thin-walled sections 138 of the inner housing 111. The thin-walled sections 138 can possess material resiliency, allowing temporary deformation, such as by squeezing the lateral sides of the inner housing 111 to temporarily displace the first latch projections 133 and the second latch projections 134 generally inward towards the longitudinal centerline axis.

[0080] As further depicted in FIGS. 13-15, the sliding outer housing 150 can be disposed over the inner housing 111. The sliding outer housing 150 can include an elongated body having a first end 153 into which the inner housing 111 is inserted, and an opposite second end 154 configured to mate with a coupling housing 95 (as depicted in FIG. 16). In certain embodiments, the elongated body of the sliding outer housing 150 can define a longitudinal bore 151 extending between the first end 153 and the second end 154.

[0081] The exterior wall of the sliding outer housing 150 can define one or more latch projection windows 156, each including a first stop surface 157 and a second stop surface 158. In embodiments, the second end 124 of the inner housing 111 can be inserted into the first end 153 of the sliding outer housing 150, allowing both the first latch projections 133 and the second latch projections 134 to traverse the longitudinal bore 151 to at least partially project through the one or more latch projection windows 156. In some embodiments, the first latch projection 133, due to its shorter lateral extensiondistance D 1 , can pass through the longitudinal bore 151 without resistance until it reaches the first stop surface 157. The second latch projection 134, which extends laterally outward by distance D2, can utilize the ramp surface 137 to temporarily deform the exterior walls of the sliding outer housing 150, thereby enabling positioning of the second latch projection 134 within the latch projection window 156.

[0082] Subsequently, the sliding outer housing 150 can be configured to slide or shift relative to the inner housing 111. For example, as depicted in FIGS. 14-15, the sliding outer housing 150 can move between a forward position (as shown in FIG. 14), where the stop surface 136 of the second latch projection 134 abuts the second stop surface 158 of the latch projection window 156, and an aft position (as shown in FIG. 15), where a surface of the first latch projection 133 abuts the first stop surface 157 of the latch projection window 156.

[0083] As further depicted in FIG. 16, the second end 154 of the sliding outer housing 150 can be configured to be positioned within a coupling housing 95, for example, to facilitate coupling with another optical fiber connector. In some embodiments, the coupling housing 95 can define a keyway 96, configured to receive a key 159 located on the exterior surface of the sliding outer housing 150. The key 159 can serve both as a rotational orientation reference for proper connection with the coupling housing 95, as well as a stop surface to ensure that the optical fiber connector 100 is inserted into the coupling housing 95 to the appropriate depth.

[0084] During insertion, the end portion 118 of the ferrule 115 can be received within an alignment sleeve 97 within the coupling housing 95. Upon reaching the appropriate insertion distance, the first latch proj ections 133 of the inner housing 111 can be configured to engage with a pair of first lift latch members 98 defined on the inner surface of the coupling housing 95, thereby inhibiting retraction of the optical fiber connector 100 from the coupling housing 95.

[0085] Release of the optical fiber connector 100 from the coupling housing 95 can be achieved by applying a pulling force on the sliding outer housing 150, which triggers a backward movement of the sliding outer housing 150 relative to the inner housing 111. In some embodiments, a ramp surface 152 defined by the sliding outer housing 150 can lift the first lift latch members 98 defined by the coupling housing 95. Once disengaged, the optical fiber connector 100 can be removed from the coupling housing 95.

[0086] Second Embodiment

[0087] Referring to FIGS. 17-21, an optical fiber connector 200 is depicted in accordance with a second embodiment of the disclosure. Similar to the first embodiment, the optical fiber connector 200 includes an inner housing 211 configured to receive a ferrule 215. The inner housing 211 is slidably positioned within a sliding outer housing 250. In some embodiments, a crimp eyelet 212 and a cable boot 213 can optionally be coupled to a first end 223 of the inner housing 211. Additionally, a dust cap 255 can optionally be positioned over an exposed end of the ferrule 215. In alternative embodiments, any of the crimp eyelet 212, cable boot 213, and dust cap 255 can be omitted.

[0088] Precise alignment of optical fiber cores within ferrules 215 can be important in the construction of low-loss optical fiber connections. One significant challenge in achieving such alignment arises from the phenomenon of eccentricity. Eccentricity is defined as the distance between a longitudinal centroidal axis of the ferrule 215 at its polished end face 214 and the centroidal axis of the optical fiber 222 (as better depicted in FIGS. 22-24) held within the passageway 217 of the ferrule 215. This misalignment is the result of multiple factors, including potential non-concentricity of the ferrule's passageway 217 relative to the outer surface of the cylindrical body 216, possible off- center positioning of the optical fiber 222 within the passageway 217, and nonconcentricity of the fiber core relative to the outer surface of the optical fiber 222 itself. Consequently, the fiber cores can fail to achieve sufficient alignment, resulting in increased insertion loss. Moreover, the tolerances required to control eccentricity and achieve such alignment contribute to the manufacturing costs of optical fiber connectors.

[0089] However, when the eccentricities of the two optical fiber ends to be joined are similar, a low-loss connection can be achieved by rotating one ferrule 115 relative to the other until maximum coupling is observed. This rotational adjustment, also referred to as “tuning,” compensates for the misalignment caused by the eccentricities. The optical fiber connector 200, as depicted in FIGS. 17-33, addresses this issue by incorporating an adjustable inner housing 211 to mitigate the effects of eccentricity.

[0090] With additional reference to FIGS. 22-25, the ferrule 215 can be defined by a substantially cylindrical body 216 extending along a longitudinal centerline axis. The ferrule 215 can be composed of a ceramic material, or similar material, and can include an optical fiber receiving passageway 217 formed along the longitudinal centerline axis (as depicted in FIG. 24). In certain embodiments, the optical fiber receiving passageway217 can feature a larger diameter, funnel-shaped opening configured to receive an optical fiber along with its coating. An adhesive can be introduced into the optical fiber receiving passageway 217 to secure the optical fiber 222 in the desired position. Alternatively, the optical fiber can be mechanically attached to the ferrule 215.

[0091] An end of the ferrule 215 can include an end portion 218, which may be conical (e.g., beveled), stepped, or flat, terminating in a polished end face 214, and is configured to facilitate the insertion of the ferrule 215 into an alignment sleeve 97.

[0092] In some embodiments, the inner housing 211 can be overmolded onto the ferrule 215 to create a secure connection. In such embodiments, a notch 219 can be defined along the body, positioned transversely to the longitudinal centerline axis, for example, in proximity to the end of the ferrule 215 opposite to the end portion 218. The notch 219 can serve as a mechanical anchor during the overmolding process, ensuring that the ferrule 215 is securely held within the inner housing 211.

[0093] In embodiments where the ferrule 215 is press fit into the inner housing 211, the inner housing 211 can define a ferrule receiving socket 220, which is shaped and sized to accommodate the substantially cylindrical body of the ferrule 215.

[0094] A retaining ridge 221 can be defined within the ferrule receiving socket 220 and can be configured to engage with the notch 219 defined by the ferrule 215, which can serve to secure the ferrule 215 within the ferrule receiving socket 220 both axially along the longitudinal centerline axis and rotationally about the longitudinal centerline axis.

[0095] The ferrule 215 extends in a cantilevered manner from the ferrule receiving socket 220 within a shroud 227 defined by the inner housing 211, with the end portion218 extending slightly beyond a second end 224 of the inner housing 211 (as depicted in FIG. 25). In some embodiments, a dust cap 225 can be positioned over the end portion 218 of the ferrule 215 (as depicted in FIGS. 18-21) to protect the polished end face 214 of the ferrule 215.

[0096] To facilitate the passage of the optical fiber, the inner housing 211 can further define an optical fiber conduit 226, which extends from the ferrule receiving socket 220 to the first end 223 of the inner housing 211. In some embodiments, the optical fiber conduit 226 is tapered along the longitudinal centerline axis, featuring a smaller diameter portion 228 in proximity to the ferrule receiving socket 220 and a relatively larger diameter portion 229 near the first end 223. This tapering generally facilitates the positioning and assembly of the ferrule 215 within the inner housing 211. The tapereddesign of the optical fiber conduit 226 also enables some movement of the optical fiber within the conduit while directing adhesive applied at the first end 223 towards the ferrule 215.

[0097] In some embodiments, a crimp surface 231, which can be substantially cylindrical in shape and centered about the longitudinal centerline axis, can be defined in proximity to the first end 223 of the inner housing 211. Additionally, in some embodiments, the crimp surface 231 can include a plurality of laterally extending ribs 232, designed to ensure a secure fit between the crimp surface 231 and the crimp eyelet 212, which can be positioned around the crimp surface 231. A cable boot can optionally be positioned over the first end 223 of the inner housing 211, thereby shielding and securing the crimp surface and a crimp eyelet. In alternative embodiments, either the crimp eyelet or the cable boot, or both, can be omitted.

[0098] In some embodiments, the exterior of the inner housing 211 can generally have a quadrilateral cross-sectional shape, transverse to the longitudinal centerline axis, and can define four chamfered comers 235. The chamfered comers 235 can enable proper alignment of the inner housing 211 relative to the sliding outer housing 250 in one of four possible rotational orientations, enabling rotational adjustment of the optical fiber ends to achieve a lower loss connection.

[0099] As depicted in FIGS. 26-28, the lateral exterior sides of the inner housing 211 define a primary pair of first latch projections 233 A and a primary pair of second latch projections 234A, as well as a secondary pair of first latch projections 233B and a secondary pair of second latch projections 234B. The primary pair of first latch projections 233 A and the primary pair of second latch projections 234A can be positioned on opposing surfaces, while the secondary pair of first latch projections 233B and the secondary pair of second latch projections 234B can be positioned on opposing surfaces, substantially orthogonal to the primary latch projections.

[0100] As depicted in FIG. 26-27, the first latch projections 233A, 233B can extend laterally outward from the longitudinal centerline axis by a first distance DI, while the second latch projections 234 A, 234B can extend laterally outward by a second distance D2, where D2 is greater than D 1. Consequently, the second latch projections 234A, 234B generally extend further from the longitudinal centerline axis than the first latch projections 233A, 233B. Additionally, the second latch projections 234A can include a stop surface 236 and a ramp surface 237, which are configured to enable assembly and facilitate sliding operation with the sliding outer housing 250. Furthermore, in someembodiments, both the first latch projections 233A, 233B and the second latch projections 234A, 234B can be formed on thin-walled sections 238A, 238B of the inner housing 211. The thin- walled sections 238 A, 238B can possess material resiliency, allowing temporary deformation, such as by squeezing the lateral sides of the inner housing 211 to temporarily displace the first latch projections 233A, 233B and the second latch projections 234A, 234B generally inward, towards the longitudinal centerline axis.

[0101] As further depicted in FIGS. 29-30, the sliding outer housing 250 can be disposed over the inner housing 211. The sliding outer housing 250 includes an elongated body having a first end 253 into which the inner housing 211 is inserted, and an opposite second end 254 configured to mate with a coupling housing 95 (as depicted in FIG. 33). In some embodiments, the elongated body of the sliding outer housing 250 can define a longitudinal bore 251 extending between the first end 253 and the second end 254.

[0102] The exterior wall of the sliding outer housing 250 can define one or more latch projection windows 256, each including a first stop surface 257 and a second stop surface 258. In embodiments, the second end 224 of the inner housing 211 can be inserted into the first end 253 of the sliding outer housing 250, allowing either of the primary pair of first latch projections 233A and the second latch projections 234A, or the secondary pair of first latch projections 233B and the second latch projections 234B to traverse the longitudinal bore 251 to be positioned within the one or more latch projection windows 256.

[0103] In some embodiments, the first latch projections 233A, 233B, due to their shorter lateral extension distance D 1 , can pass through the longitudinal bore 251 without resistance until it reaches the first stop surface 257. The second latch projection 234A, 234B, which extend laterally outward by distance D2, can utilize a ramp surface 237 to temporarily deform the exterior walls of the sliding outer housing 250, thereby positioning the second latch second latch projection 234A, 234B within the latch projection window 256.

[0104] Subsequently, the sliding outer housing 250 is configured to slide or shift relative to the inner housing 211. For example, as depicted in FIGS. 31-32, the sliding outer housing 250 can move between a forward position (as shown in FIG. 31), where the stop surface 236 of the second latch projection 234 abuts the second stop surface 258 of the latch projection window 256, and an aft position (as shown in FIG. 32), where a surface of the first latch projection 233 abuts the first stop surface 257 of the latch projection window 256.

[0105] The inner housing 211 can be positioned within the sliding outer housing 250 in one of four distinct rotational orientations, corresponding to the alignment of either the primary pair of latch projections 233A, 234A or the secondary pair of latch projections 233B, 234B with the latch projection windows 256 of the sliding outer housing 250. Selective orientation enables the rotational adjustment or tuning of the ferrule 215 within the connector assembly to compensate for any misalignments caused by eccentricities. By selecting a rotational orientation during assembly, the alignment of the optical fiber cores can be fine-tuned to reduce insertion loss and improve signal transmission.

[0106] As further depicted in FIG. 33, the second end 254 of the sliding outer housing 250 can be configured to be positioned within a coupling housing 95, for example, to facilitate coupling with another optical fiber connector. In some embodiments, the coupling housing 95 can define a keyway 96, configured to receive a key 259 located on the exterior surface of the sliding outer housing 250. The key 259 can serve both as a rotational orientation reference for proper connection with the coupling housing 95, as well as a stop surface to ensure that the optical fiber connector 200 is inserted into the coupling housing 95 to the appropriate depth.

[0107] During insertion, the end portion 218 of the ferrule 215 is received within an alignment sleeve 97 within the coupling housing 95. Upon reaching the appropriate insertion distance, the first latch projections 233A or 233B of the inner housing 211 are configured to engage with a pair of first latch members 98 defined on the inner surface of the coupling housing 95, thereby inhibiting retraction of the optical fiber connector 200 from the coupling housing 95.

[0108] Release of the optical fiber connector 200 from the coupling housing 95 can be achieved by applying a pulling force on the sliding outer housing 250, which triggers a backward movement of the sliding outer housing 250 relative to the inner housing 211. In some embodiments, a ramp surface 252 defined by the sliding outer housing 250 can first lift latch members 98 defined by the coupling housing 95 to disengage from the latch projections 233A, 233B. Once disengaged, the optical fiber connector 100 can be removed from the coupling housing 95.

[0109] Third Embodiment

[0110] Referring to FIGS. 34-38, an optical fiber connector 300 is depicted in accordance with a third embodiment of the disclosure. The optical fiber connector 300includes an inner housing 311 configured to receive a ferrule 315. Unlike the first embodiment, the optical fiber connector 300 does not include a sliding outer housing. Instead, the inner housing 311 is designed to be directly coupled to a coupling housing 95 (as depicted in FIG. 45). In some embodiments, a crimp eyelet 312 and a cable boot 313 can optionally be coupled to a first end 323 of the inner housing 311. Additionally, a dust cap 355 can optionally be positioned over an exposed end of the ferrule 315. In other embodiments, any of the crimp eyelet 312, cable boot 313, and dust cap 355 can be omitted.

[0111] Embodiments of the present disclosure provide a springless optical fiber connector 300, wherein the traditionally multi-component, overmolded ferrule assembly, including a compression spring, can be replaced with a unitary, single-piece inner housing 311 configured to receive a ferrule 315. This embodiment presents a lower-cost optical fiber connector 300 that remains compatible with a spring-biased connector to complete an optical connection.

[0112] With additional reference to FIGS. 39-42, the ferrule 315 can be defined by a substantially cylindrical body 316 extending along a longitudinal centerline axis. The ferrule 315 can be composed of a ceramic material, or similar material, and can include an optical fiber receiving passageway 317 formed along the longitudinal centerline axis (as depicted in FIGS. 41-42). In some embodiments, the optical fiber receiving passageway 317 can feature a larger diameter, funnel-shaped opening configured to receive an optical fiber 322 along with its coating. An adhesive can be introduced into the optical fiber receiving passageway 317 to secure the optical fiber in the desired position. Alternatively, the optical fiber can be mechanically attached to the ferrule 315.

[0113] An end of the ferrule 315 can include an end portion 318, which may be conical (e.g., beveled), stepped, or flat, terminating in a polished end face 314 and can be configured to facilitate the insertion of the ferrule 315 into an alignment sleeve 97.

[0114] In some embodiments, the inner housing 311 can be overmolded onto the ferrule 315 to create a secure connection. In such embodiments, a notch 319 can be defined along the body, positioned transversely to the longitudinal centerline axis, for example, in proximity to the end of the ferrule 315 opposite the end portion 318. The notch 319 can serve as a mechanical anchor during the overmolding process, ensuring that the ferrule 315 is securely held within the inner housing 311.

[0115] In embodiments where the ferrule 315 is press fit into the inner housing 311, the inner housing 311 can define a ferrule receiving socket 320, which is shaped and sized to accommodate the substantially cylindrical body of the ferrule 315.

[0116] A retaining ridge 321 can be defined within the ferrule receiving socket 320 and can be configured to engage with the notch 319 defined by the ferrule 315, which serves to secure the ferrule 315 within the ferrule receiving socket 320 both axially along the longitudinal centerline axis and rotationally about the longitudinal centerline axis.

[0117] Following insertion, the ferrule 315 can extend in a cantilevered manner from the ferrule receiving socket 320 within a shroud 327 defined by the inner housing 311, with the end portion 318 extending slightly beyond a second end 324 of the inner housing 311 (as depicted in FIG. 42). As further depicted in FIGS. 43-44, in some embodiments, a dust cap 355 can be positioned over the end portion 318 of the ferrule 315 to protect the polished end face 314 of the ferrule 315.

[0118] To facilitate the passage of the optical fiber, the inner housing 311 can further define an optical fiber conduit 326, which can extend from the ferrule receiving socket 320 to the first end 323 of the inner housing 311. In some embodiments, the optical fiber conduit 326 can be tapered along the longitudinal centerline axis, featuring a smaller diameter portion 328 in proximity to the ferrule receiving socket 320 and a relatively larger diameter portion 329 in proximity to the first end 323. Tapering of the optical fiber conduit 326 can generally facilitate the positioning and assembly of the optical fiber 322 and ferrule 315 within the inner housing 311 by enabling some movement of the optical fiber within the optical fiber conduit 326 while directing adhesive applied at the first end 323 towards the ferrule 315.

[0119] With continued reference to FIG. 42, in some embodiments, the first end 323 of the inner housing 311 can define a crimp surface 331, which can be substantially cylindrical in shape and centered about the longitudinal centerline axis. Additionally, in some embodiments, the crimp surface 331 can include a plurality of laterally extending ribs 332, designed to ensure a secure fit between the crimp surface 331 and the crimp eyelet 312, which can be positioned around the crimp surface 331. As further depicted in FIGS. 43-44, the cable boot 313 can optionally be positioned over the first end 323 of the inner housing 311, thereby shielding and securing the crimp surface 331 and crimp eyelet 312. In alternative embodiments, either the crimp eyelet 312 or the cable boot 313, or both, can be omitted.

[0120] As depicted in FIG. 42, one or more lateral exterior sides of the inner housing311 can define a first latch projection 333. For instance, in certain embodiments, the inner housing 311 can define a pair of first latch projections 333, for example, positioned on opposing exterior lateral sides of the inner housing 311. Furthermore, in some embodiments, the first latch projections 333 can be formed on thin-walled sections 338 of the inner housing 311. The thin-walled sections 338 can possess material resiliency, allowing temporary deformation, such as by squeezing the lateral sides of the inner housing 311 to temporarily displace the first latch projections 333 generally inward towards the longitudinal centerline axis.

[0121] As further depicted in FIG. 45, the second end 324 of the inner housing 311 can be directly positioned within a coupling housing 95, facilitating the coupling of the optical fiber connector 300 with another optical fiber connector. During insertion, the end portion 318 of the ferrule 315 can be received within an alignment sleeve 97 within the coupling housing 95. Upon reaching the appropriate insertion distance, the first latch projections 333 of the inner housing 311 can engage with a pair of first latch members 98 defined on the inner surface of the coupling housing 95, thereby inhibiting retraction of the optical fiber connector 300 from the coupling housing 95.

[0122] Release of the optical fiber connector 300 from the coupling housing 95 can be achieved by rotating the optical fiber connector 300 approximately 90° about the longitudinal centerline axis, which disengages the first latch projections 333 from the first latch members 98, for example by lifting the first latch members 98 of the coupling housing 95, and allowing the optical fiber connector 300 to be removed from the coupling housing 95.

[0123] Reference will now be made in detail to exemplary aspects of the present disclosure that are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

[0124] Having described the preferred aspects and implementations of the present disclosure, modifications and equivalents of the disclosed concepts can readily occur to one skilled in the art. However, it is intended that such modifications and equivalents be included within the scope of the claims which are appended hereto.

Claims

CLAIMSWhat is claimed is:

1. An optical fiber connector, comprising: an inner housing defining a ferrule receiving socket and an optical fiber conduit extending along a longitudinal centerline axis, the inner housing having a first end and a second end; a ferrule disposed within the ferrule receiving socket, the ferrule comprising a free end extending beyond the second end of the inner housing, wherein the inner housing is overmolded over a portion of the ferrule; and a sliding outer housing disposed over the inner housing, the sliding outer housing comprising an elongated body defining a longitudinal bore extending between a first end and an opposite second end, the second end of the sliding outer housing being configured to mate with a coupling housing.

2. The optical fiber connector of claim 1, wherein the sliding outer housing further defines a latch projection window, and the inner housing defines a first latch projection and a second latch projection positioned on a lateral exterior side of the inner housing, and wherein upon insertion of the inner housing into the sliding outer housing, the first latch projection is configured to engage with a first stop surface defined by the latch projection window, and the second latch projection is configured to engage with a second stop surface defined by the latch projection window, enabling sliding movement of the sliding outer housing relative to the inner housing between a forward position and an aft position.

3. The optical fiber connector of claim 2, wherein the first latch projection extends a first distance laterally outward from the longitudinal centerline axis, and the second latch projection extends a second distance laterally outward from the longitudinal centerline axis, the second distance being greater than the first distance.

4. The optical fiber connector of claim 2, wherein the second latch proj ection further comprises a stop surface and a ramp surface.

5. The optical fiber connector of claim 2, wherein the first latch projection and the second latch projection are formed on thin-walled sections of the inner housing having a material resiliency enabling temporary deformation for assembly with the sliding outer housing.

6. The optical fiber connector of claim 1, wherein the ferrule is made of a ceramic material.

7. The optical fiber connector of claim 1, wherein the optical fiber conduit defined by the inner housing is tapered along the longitudinal centerline axis, with a smaller diameter portion in proximity to the ferrule receiving socket and a relatively larger diameter portion in proximity to the first end of the inner housing.

8. The optical fiber connector of claim 1 , further comprising a crimp surface defined on the first end of the inner housing, the crimp surface having a substantially cylindrical shape centered about the longitudinal centerline axis and including a plurality of laterally extending ribs configured to secure a crimp eyelet around the crimp surface.

9. The optical fiber connector of claim 1, further comprising a key defined on an exterior surface of the sliding outer housing, the key being configured to engage with a keyway defined in the coupling housing to provide a rotational orientation reference and a stop surface for proper insertion depth of the optical fiber connector into the coupling housing.

10. The optical fiber connector of claim 1, further comprising a dust cap configured to be positioned over a portion of the ferrule when the optical fiber connector is not in use.

11. An optical fiber connector, comprising: an inner housing defining a ferrule receiving socket and an optical fiber conduit extending along a longitudinal centerline axis, the inner housing having a first end and a second end; a ferrule disposed within the ferrule receiving socket, the ferrule comprising a free end extending beyond the second end of the inner housing;a sliding outer housing disposed over the inner housing, the sliding outer housing comprising an elongated body defining a longitudinal bore extending between a first end and an opposite second end, the second end of the sliding outer housing being configured to mate with a coupling housing; one or more latch projections formed on exterior sides of the inner housing, the one or more latch projections extending laterally outward from the longitudinal centerline axis and configured to engage with corresponding latch projection windows defined in the sliding outer housing; and wherein the inner housing can be positioned within the sliding outer housing in one of four distinct rotational orientations, enabling rotational adjustment of the ferrule to compensate for misalignments caused by an eccentric position of an optical fiber within the ferrule.

12. The optical fiber connector of claim 11, wherein an optical fiber receiving passageway defined by the ferrule comprises a larger diameter funnel-shaped opening configured to receive the optical fiber along with its coating.

13. The optical fiber connector of claim 11, wherein the ferrule is composed of a ceramic material.

14. The optical fiber connector of claim 11 , wherein the inner housing is overmolded over a portion of the ferrule.

15. The optical fiber connector of claim 11 , wherein the inner housing defines a crimp surface having a substantially cylindrical shape and centered about the longitudinal centerline axis, the crimp surface further comprising a plurality of laterally extending ribs.

16. The optical fiber connector of claim 15, further comprising a crimp eyelet coupled to a first end of the inner housing and a cable boot positioned over the first end.

17. The optical fiber connector of claim 11, wherein the optical fiber conduit is tapered along the longitudinal centerline axis, featuring a smaller diameter portion inproximity to the ferrule receiving socket and a relatively larger diameter portion near the first end of the inner housing.

18. The optical fiber connector of claim 11, wherein the second end of the sliding outer housing is configured to be positioned within the coupling housing, the coupling housing defining a keyway configured to receive a key located on an exterior surface of the sliding outer housing.

19. The optical fiber connector of claim 11 , wherein the one or more latch proj ections are formed on thin-walled sections of the inner housing having a material resiliency enabling temporary deformation for assembly with the sliding outer housing.

20. An optical fiber connector, comprising: an inner housing defining a ferrule receiving socket and an optical fiber conduit extending along a longitudinal centerline axis, the inner housing having a first end and a second end; a ferrule disposed within the ferrule receiving socket, the ferrule comprising a free end extending beyond the second end of the inner housing; one or more latch projections formed on exterior lateral sides of the inner housing, the one or more latch projections extending laterally outward from the longitudinal centerline axis and configured to engage with corresponding a latch member defined on an inner surface of a coupling housing; wherein the inner housing is configured to be directly coupled to the coupling housing, such that upon insertion of the ferrule into an alignment sleeve within the coupling housing, the one or more latch projections engage with the latch member to inhibit retraction of the optical fiber connector from the coupling housing; and wherein release of the optical fiber connector from the coupling housing is achieved by rotating the optical fiber connector approximately 90° about the longitudinal centerline axis, thereby disengaging the one or more latch projections from the latch member.

21. The optical fiber connector of claim 20, wherein the ferrule is composed of a ceramic material.

22. The optical fiber connector of claim 20, wherein an optical fiber receiving passageway defined by the ferrule comprises a larger diameter funnel-shaped opening configured to receive an optical fiber along with its coating.

23. The optical fiber connector of claim 20, wherein the inner housing is overmolded over a portion of the ferrule.

24. The optical fiber connector of claim 20, wherein the inner housing defines a crimp surface having a substantially cylindrical shape and centered about the longitudinal centerline axis, the crimp surface further comprising a plurality of laterally extending ribs.

25. The optical fiber connector of claim 24, further comprising a crimp eyelet coupled to a first end of the inner housing and a cable boot positioned over the first end.

26. The optical fiber connector of claim 20, wherein the optical fiber conduit is tapered along the longitudinal centerline axis, featuring a smaller diameter portion in proximity to the ferrule receiving socket and a relatively larger diameter portion near the first end of the inner housing.

27. The optical fiber connector of claim 20, wherein the one or more latch projections are formed on thin-walled sections of the inner housing, the thin-walled sections possessing material resiliency that allows temporary deformation.

28. The optical fiber connector of claim 20, further comprising a dust cap configured to be positioned over a beveled portion of the ferrule.

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