Ferrules and ferrule assemblies for fiber optic connectors having self-alignment features

Abstract

Ferrules and ferrule assemblies for fiber optic connectors are disclosed that having self-alignment features that improve mating when misaligned. The ferrules may comprise one or more lead-in portions having geometry such as a front end with a ball-shaped portion for improving self-alignment and inhibit excess force of binding during optical mating. The ferrules or ferrule assemblies may use fiber-based or lens-based optical interfaces along with other features as desired. Fiber optic connectors may have other self-aligning features that may be used with the ferrules or ferrule assemblies disclosed herein or with conventional ferrules as desired. One or more ferrules or ferrule assemblies may be disposed within an optical housing of the fiber optic connector such as forming a duplex connector.

Description

FERRULES AND FERRULE ASSEMBLIES FOR FIBER OPTIC CONNECTORS HAVING SELF-ALIGNMENT FEATURESRELATED APPLICATIONS

[0001] This application claims the benefit of priority of U. S. Provisional Application Serial No. 63 / 714,260 filed on October 31, 2024, the content of which is relied upon and incorporated herein by reference in its entirety.FIELD

[0002] The disclosure is directed to ferrules and ferrule assemblies for use in fiber optic connectors. The ferrules and ferrule assemblies comprise features at the front end of the ferrule that accommodate lateral misalignment of the ferrule when mating with a suitable device. The ferrule and ferrule assemblies may be used as a portion of fiber optic connectors for mating with another connector or device that receives a portion of the ferrule or ferrule assembly during mating.BACKGROUND

[0003] Optical fiber is increasingly being used for a variety of applications, including but not limited to broadband voice, video, and data transmission in a variety of new and expanding applications. As bandwidth demands increase optical fiber is migrating deeper into new and emerging applications for communication networks and systems having requirements that are different from the networks and systems of conventional operator networks. One such new application is for the use of optical fiber for in-vehicle optical networks and the like. As optical fiber extends deeper into these communication networks there exist a need for quickly and easily making optical connections while meeting the requirements and demands for these new and emerging applications.

[0004] Fiber optic connectors were developed for making one or more plug and play optical connections using a suitable fiber optic connector for the given application. Fiber optic connectors provide a node for mating and unmating in the optical network and provide the flexibility of locating the connection points in convenient locations for efficient network assembly, access, design and / or deployment. Conventional fiber optic connectors used for telecommunications, are used indoors or inside enclosures for inhibiting moisture, dust, dirt or debris or the like from reaching the mating interface of the fiber optic connector. Hardened fiber optic connectors were developed for outdoorapplications that for inhibiting moisture, dust, dirt or debris or the like from reaching the mating interface of the fiber optic connector. However, these hardened fiber optic connectors developed for outdoor applications are relatively large, bulky and / or expensive.

[0005] As new applications emerge for the deployment of optical networks the requirements for these new applications may be different and / or have other considerations for the given application. One such emerging application is the use of optical systems on vehicles that present a new environment with specific challenges for successful deployment in potential harsh environments while requiring a relatively compact footprint in a robust and reliable package while enabling reliable mating and unmating of connectors, inspection and serviceability, ease of manufacture and the like. Consequently, there exists an unresolved need for robust fiber optic connectors for reliable mating for preserving optical performance and inhibiting damage to the fiber optic connectors or device being optically connected.SUMMARY

[0006] The disclosure is directed to ferrules and ferrule assemblies having selfaligning feature for use with fiber optic connectors (hereinafter “connector(s)”) for optical mating with a complimentary device. The connectors may be configured for supporting one or more ferrules or ferrule assemblies that may be disposed within a housing of the connector when assembled. Additionally, the ferrule or ferrule assemblies may be configured for physical contact or free-space transmission as desired. Further, the ferrule or ferrule assembly may use a lens for optical transmission as desired or not. The connectors that use the ferrules and ferrules assemblies disclosed herein may have any suitable configuration desired.

[0007] One embodiment is directed to a ferrule comprising a fiber bore extending from a rear end into a body of the ferrule along with a front end of the ferrule comprising a lead-in portion having a ball-shaped portion for inhibiting the binding of the ferrule during insertion into a complementary device if the ferrule is laterally misaligned.

[0008] The disclosure is also directed to a ferrule assembly comprising a fiber bore extending from a rear end into the ferrule assembly and an optical interface disposed at a front end of the ferrule assembly. The ferrule assembly comprises a lead-in portion at the front end comprising a ball-shaped portion for inhibiting the binding of the ferrule assembly during insertion into a complementary device if laterally misaligned.

[0009] As used herein, “ball-shaped portion” means a generally ball shape that may be truncated in one or more planes or surfaces so that only a partial ball-shaped is formed on the front end of the ferrule or ferrule assembly and excludes a cylindrical shape that may or may not have a chamfer. In other variations, the lead-in portion of the ferrule or ferrule assembly may comprise a lead-in diameter that is smaller than a rearward nominal diameter of the ferrule. The ferrule or ferrule assembly may also comprise a second lead-in portion disposed rearward of the lead-in portion on the ferrule.

[0010] The disclosure is also directed to a fiber optic connector comprising a ferrule and an optical housing comprising an optical housing passageway extending from a front end to a rear end where the ferrule is configured to be disposed within the housing when assembled. The ferrule comprises a fiber bore extending from a rear end into the ferrule and an optical interface is disposed at a front end of the ferrule. The ferrule comprises a lead-in portion at the front end having a ball-shaped portion for inhibiting the binding of the ferrule during insertion into a complementary device if laterally misaligned.

[0011] The disclosure is further directed to a fiber optic connector comprising a ferrule and an optical housing comprising an optical housing passageway extending from a front end to a rear end where the ferrule is configured to be disposed within the optical housing when assembled. The ferrule comprises a fiber bore extending from a rear end into the ferrule and an optical interface is disposed at a front end of the ferrule. The ferrule comprises a lead-in portion at the front end comprising a ball-shaped portion and the lead-in portion comprises a lead-in diameter that is smaller than a rearward nominal diameter of the ferrule for inhibiting the binding of the ferrule during insertion into a complementary device if laterally misaligned.

[0012] The disclosure is further directed to a fiber optic connector comprising a ferrule assembly and an optical housing comprising an optical housing passageway extending from a front end to a rear end where the optical housing passageway is configured for receiving a portion of the ferrule assembly when assembled. The ferruleassembly comprises a ferrule having a fiber bore extending from a rear end into the ferrule assembly and an optical interface disposed at a front end of the ferrule. The optical housing passageway has a passageway diameter that is at least 1.25 times larger than a portion of the ferrule assembly that is disposed through the optical housing passageway adjacent to the optical housing passageway when assembled. A retention member may be attached to a portion of the ferrule or ferrule assembly and act as a stop for the forward movement of the ferrule or ferrule assembly with respect to an optical housing.

[0013] Still other variations are possible for the ferrule or ferrule assemblies disclosed for use with connectors. Likewise, the connectors may further include further features as disclosed and desired. Connector features or structures may include housings, latching, sealing, ability to disassemble for service, inspection or cleaning, connector position assurance (CPAs) and the like.

[0014] Additional features and advantages will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the same as described herein, including the detailed description that follows, the claims, as well as the appended drawings.

[0015] It is to be understood that both the foregoing general description and the following detailed description present embodiments that are intended to provide an overview or framework for understanding the nature and character of the claims. The accompanying drawings are included to provide a further understanding of the disclosure and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments and together with the description serve to explain the principles and operation.BRIEF DESCRIPTION OF THE FIGURES

[0016] FIGS. 1A-1C are schematic representations of a prior art ferrule assembly that is misaligned when being inserted into a complimentary' device for depicting the binding or damage that may be caused by misalignment of the prior art ferrule assembly;

[0017] FIGS. 2A-2F are schematic representations of an explanatory ferrule of the present application that is misaligned when being inserted into a complimentary device for depicting the operation of the self-aligning features of the ferrule for inhibiting damage and providing improved mating compared with the prior art ferrule assembly of FIGS. 1A-1C;

[0018] FIG. 3 is a close-up view of another explanatory' ferrule of the present application showing the details of self-aligning features that may be used with ferrules according to the present application;

[0019] FIG. 4 is a schematic cross-sectional representation of a fiber optic connector having the ferrule of FIG. 3 being disposed in a ferrule holder within the optical housing of the fiber optic connector and aligned for mating with a complementary device;

[0020] FIG. 5 is a schematic cross-sectional representation of the fiber optic connector of FIG. 4 being inserted into the complementary device with the optical housing engaging the inner alignment features of the complementary' device;

[0021] FIG. 6 is a schematic cross-sectional representation of the fiber optic connector of FIG. 4 being further inserted into the complementary device with the ferrule holder of the ferrule assembly approaching the outer lead-in portion of the complementary' device;

[0022] FIG. 7 is a schematic cross-sectional representation of the fiber optic connector of FIG. 4 being inserted into the complementary' device so that the ferrule holder of the ferrule assembly provides gross alignment in the complementary device using the outer lead-in for positioning the ferrule of the fiber optic connector as it approaches during mating;

[0023] FIG. 8 is a schematic cross-sectional representation of the fiber optic connector of FIG. 4 being inserted into the complementary device so that the ferrule of the ferrule assembly engages the inner lead-in of the complementary device during mating;

[0024] FIG. 9 is a schematic cross-sectional representation of the fiber optic connector of FIG. 4 mate with the complementary' device for optical communication between the fiber optic connector and the complementary device;

[0025] FIG. 10 is a schematic cross-sectional representation of another fiber optic connector that includes a retaining member for assembling the ferrule assembly in thefiber optic connector and terminated on a fiber optic cable according to the concepts disclosed herein;

[0026] FIG. 11 is a partial sectional view of a terminated fiber optic connector similar to FIG. 10 with the optical housing disposed within a connector body and using the retaining member for assembling the ferrule assembly in the fiber optic connector according to the concepts disclosed herein;

[0027] FIG. 12 is a bottom perspective view of an explanatory fiber optic connector showing the connector body having a longitudinal open slot cooperating with a protrusion of the optical housing for assembly of the optical housing with the connector body using the concepts disclosed; and

[0028] FIG. 13 is a partially exploded view depicting an explanatory hybrid fiber optic connector suitable for use with the concepts disclosed herein that is suitable for both optical mating and electrical connection using the concepts disclosed.DETAILED DESCRIPTION

[0029] The disclosure is directed to ferrules and ferrule assemblies for use with fiber optic connectors (hereinafter “connector(s)”) that are useful for optical mating with a complimentary device. The connectors may be configured for supporting one or more ferrules or ferrule assemblies that may be disposed within a housing of the connector when assembled. The explanatory connectors are depicted as a plug connector having a ferrule that is configured for mating with complementary device. The complementary device is configured as a receptacle that receives a portion of the ferrule and plug connector for mating and providing optical connectivity. The connector may terminate one or more cables for creating a cable assembly. The complementary device may be configured as a termination to one or more cables or be arranged as a portion of a device such as a module or as part of an assembly such as the being mounted to a circuit board or the like.

[0030] The concepts of ferrule and ferrule assemblies with self-aligning features disclosed herein may be used with any suitable connector. By way of example, and not limitation, the connector may comprise a housing and / or connector body along with other components as desired. For instance, the connector may comprise an integrally-formedlatching trigger for unmating the connector when desired. The complementary devices may be configured with the receptacle and may comprise cooperative features for alignment or mating with the connector as desired. Connectors may also comprise one or more electrical terminals in addition to the ferrules disposed within an optical housing when assembled for creating a hybrid electrical and optical connector.

[0031] The ferrule concepts disclosed may be used as a portion of a ferrule assembly comprising a ferrule holder or not as desired. The ferrule may have self-alignment features disposed adjacent to a front end to aid insertion if a misalignment occurs between the ferrule and the complementary' device and avoid relatively large insertion forces during mating and / or damage. Similarly, the ferrule holder may have features for aiding with gross alignment of the ferrule during mating and inhibit relatively large insertion forces or binding. Additionally, the geometry' between the ferrule holder and a housing of the connector may cooperate to allow lateral movement of the ferrule or ferrule assembly relative to the housing of the connector during the mating of the connector with a complimentary' device if desired. The concepts disclosed may be used in various combinations for the desired connector as desired and appropriate. For instance, the disclosed features on the ferrule, ferrule holder or the cooperation between the ferrule holder and housing be used individually or in combination as desired for improving mating if a misalignment of the ferrule occurs.

[0032] The ferrule or ferrule assembly may be formed from any suitable material or variations depending on the desired application. For instance, the ferrule holder and ferrule may be formed from two different materials and assembled together to form the ferrule assembly if desired. By way of example, the ferrule could be a ceramic material such as zirconia, optically transparent polymer or other material while the ferrule holder could be a different material. In other variations, the ferrule and a portion that acts as the ferrule holder may be molded as a single monolithic component such as molded from an optically transmissive polymer or other suitable material. The ferrule or ferrule assembly may be a portion of any suitable connector as well and the intended connector design may influence the design of ferrule or ferrule assembly used.

[0033] The ferrule or ferrule assembly disclosed may comprises an optical interface disposed at the front end that may use physical contact such as between optical fibers, lenses, etc. or a spaced apart optical interface such as using lenses for opticalcommunication as desired. As used herein, the term “ferrule assembly” may comprise a single component (e.g,, mon olithi call y molded ferrule and ferrule holder) or multiple components (e.g., separate ferrule and ferrule holder) as desired. By way of example, the ferrule assembly may be formed as a single molded component with a molded-in lens if desired or formed from multiple components such as a ferrule holder formed from a polymer used with a ferrule such as a conventional ceramic ferrule or molded ferrule with a molded or attached lens. Although, the ferrule assemblies depicted are shown as singlefiber optical interfaces the concepts disclosed may be used with optical interfaces that support multiple optical fibers in a single ferrule or ferrule assembly if desired.

[0034] The ferrules or ferrule assemblies disclosed for use with connectors may comprise a front end with one or more lead-in portions that inhibit excess forces or damage if a slight misalignment occurs during mating. For instance, the lead-in portion may comprise a ball-shaped portion for inhibiting the binding during insertion into a complementary device during mating or unmating. The lead-in portion may comprise a diameter that is smaller than a rearward diameter that is positioned adj cent to the lead-in portion. The ferrules or ferrule assemblies may also comprise a second lead-in portion disposed rearward of the lead-in portion. By way of example, the second lead-in portion may comprise an angled surface. The angled surface provides a realigning force to help guide or rotate the ferrule or ferrule assembly back towards the center line of complimentary device and inhibit binding, excess forces or damage during mating or unmating. The housing of the connector may be configured for allowing the lateral movement of the ferrule or ferrule assembly during insertion as well.

[0035] The connector concepts may use optical terminals with the ferrule or ferrule assemblies that allow quick and easy manufacture for terminating a fiber optic cable in a reliable manner. The connectors may comprise a housing that is removable and / or reinstallable within a connector body that receives one or more optical terminals when assembled. The optical terminals may be arranged as one or more separate units or subassemblies when assembled. The optical terminals terminate and strain-relieve an optical fiber or fiber optic cable to the respective ferrule assemblies for providing quick and easy assembly along with reliable optical termination. For instance, the connectors may use adeformable sleeve for strain-relieving the optical fibers in the cable to the ferrule assemblies. Likewise, the connectors may comprise any suitable electrical terminal desired or none at all.

[0036] Connectors may also include other components as well as desired or not with the ferrule concepts disclosed. For instance, the connectors may optionally comprise a boot that cooperates with the connector body for receiving a portion of the optical terminal by permitting a portion of the sleeve of the respective optical terminal to fit into a boot passageway. The boot may be formed from any suitable material as desired for the design such as a thermal plastic elastomer, but the boot may be formed from more rigid plastics as well depending on the connector design and the properties desired.

[0037] Additionally, the connectors using the ferrules or ferrule assemblies may advantageously include environmental protection or cleanliness for the optical interface after being mated by using one or more sealing gaskets as desired. For instance, the sealing gasket(s) may be disposed on the ferrule assembly so that the sealing gasket provides environmental protection when the connector is optically mated with a suitable device such as a complimentary connector, transceiver or other suitable device. When assembled, the sealing gasket is disposed within a passageway of the optical housing and should not be confused with seals disposed on the outer surface of the connector housing. Instead, locating the sealing gasket on the ferrule assembly within the optical housing provides an internal sealing cavity for the optical mating within the passageway of the optical housing, thereby providing environmental protection when connector is in the mated state.

[0038] The connector used with the ferrule or ferrule assembly concepts disclosed herein may be used as part of a larger wiring harness or device. For instance, the connector may be constructed as a portion of a larger wiring harnesses or sub-assembly built by a contractor for future installation into vehicles or other devices during the manufacturing process. By way of example, the connectors could support connectivity to one or more cameras on a vehicle. Likewise, the connectors could be used for optical connections with modules, ECUs, sensors or other devices used on a vehicle.

[0039] Of course, the ferrule or ferrule assembly concepts disclosed may be used in other applications as desired. For instance, the concepts disclosed herein may also be suitable for fiber optic networks such as for Fiber-to-the-location (FTTx) and 5Gapplications and are equally applicable to other optical applications as well including indoor, indoor / outdoor such as security systems, industrial, wireless, or other suitable applications. Additionally, the concepts disclosed may be used with connectors having any suitable footprint, configuration or construction. Reference to “forward”, “front”, “rearward” and “rear”, “top” or “bottom” as used herein are relative terms that generally relate to the orientation of the connector where the front or forward portion is with respect to the direction of the mating end of the optical interface or components ) and the rear or rearward portion is with respect to the direction of the portion of the fiber optic connector where the fiber optic cable is first inserted into the fiber optic connector or component(s). Various components or structures are described in this disclosure as being forward or rearward relative to one another. Various designs, constructions, or features for hybrid connectors are disclosed in more detail with respect to explanatory embodiments as discussed herein and may be modified or varied as desired.

[0040] FIGS. 1A-1C schematically depict a conventional prior art ferrule assembly 6 having a conventional ferrule holder 4 and a prior art ferrule 5 for explaining the binding that may occur with prior art connectors if the prior art ferrule 5 is misaligned with the complimentary receptacle 8 during mating. As depicted in FIGS. 1A-1C, only the ferrule assembly 6 and portion of the receptacle 8 that receives the ferrule 5 are shown for simplicity. The misalignment may be caused by one or more factors such as tolerance stack-ups, location of parts mounted on the complementary device and the like.

[0041] FIG. 1A depicts prior art ferrule assembly 6 having a longitudinal axis (LA) taken through the fiber bore of ferrule 5. As shown, the longitudinal axis (LA) is misaligned with a centerline (CL) of the receptacle 8 with a lateral offset of a distance (D) during insertion when mating. Although the misalignment distance (D) of the prior art ferrule assembly 6 may be small the misalignment of the prior art ferrule 5 may cause issues during mating such as binding, excess forces or even damage. The arrows represent the direction of the insertion forces being applied to the prior art ferrule assembly 6 as the prior art ferrule 5 engages the complimentary receptacle 8 as it moves forward during insertion for mating.

[0042] FIG. IB depicts the prior art ferrule assembly 6 advancing into the receptacle 8. Due to the misalignment of distance (D) between the ferrule 5 and receptacle 8, the chamfer on the top front side of ferrule 5 contacts the chamfer on the top side of the receptacle 8 and creates a rotational force on the prior art ferrule assembly 6 that rotates the front end of the prior art ferrule 5 downward when entering the receptacle 8 so that the longitudinal axis (LA) of the ferrule is angled with respect to the centerline (CL) of receptacle 8. As shown, the front end of the prior art ferrule 5 is angled downward and the top portion of the ferrule 5 is inserted farther into the receptacle 8 compared with the bottom portion. As the prior art ferrule 5 is pushed further into the receptacle 8 the insertion force increases since the longitudinal axis (LA) of the ferrule 5 is entering with a displaced angle from a centerline (CL) of the receptacle 8. FIG. 1C shows the prior art ferrule 5 inserted further into the receptacle 8 in a misaligned state. Beside increased insertion forces, the misaligned prior art ferrule 5 may scrape or gouge the sidewalls of the receptacle 8 causing damage. Further, the scraping or gouging due to the misalignment can make further unmating or mating more difficult or cause further damage.

[0043] The improved ferrules 50 and ferrule assemblies 60 disclosed herein comprise one or more self-aligning features. The one or more self-alignment features that may allow reduced insertion forces and inhibit binding or damage if the ferrule 50 is laterally misaligned with the receptacle 180 of the complementary device during mating. The ferrules 50 disclosed comprises a suitable optical interface 58 disposed at the front end 53 for optical mating with a suitable device.

[0044] Self-aligning features may be formed on the front end of the ferrules 50 that may be used with ferrule assemblies 40 or connectors 100 as desired. As used herein, the front end 53 of the ferrule 50 means the front portion of the ferrule 50 over a suitable length of the ferrule 50. Self-aligning features for ferrule 50 may comprise one or more lead-in portions 55,56 disposed at the front end 53 of ferrule 50. The lead-in portion 55 of ferrules 50 may have a front end 53 having a ball-shaped portion 57 for inhibiting the binding of the ferrule 50 during insertion into a complementary device if laterally misaligned. The ball-shaped portion 57 of ferrule 50 may be truncated in one or more planes or surfaces so that only a partial ball-shaped is formed on the front end 53 of the ferrule 50. The front end 53 of ferrule 50 may use any suitable geometry including oneor more lead-in portions, portions with reduced diameters or angled surfaces that begin rearward of a first lead-in portion of the ferrule 50 for improving insertion performance. Generally speaking, if used a second lead-in portion is typically disposed rearward of the first lead-in portion 55 on the body of the ferrule 50.

[0045] FIGS. 2A-2F shows an explanatory ferrule 50 to explain the self-align ent concepts of ferrule 50 when a lateral offset is present during mating with a suitable device and FIG. 3 depicts another explanatory ferrule 50 using different geometry according to the concepts disclosed. Other ferrule geometries are also possible using the disclosed concepts.

[0046] Additionally, other self-aligning features for ferrule assemblies or connectors are also possible that may be used with the improved ferrule 50 or with a conventional ferrule according to the present disclosure. For instance, the ferrule holder 60 may have one or more features for aiding self-alignment with the complementary device by providing course alignment during insertion.

[0047] Illustratively, FIGS. 4-9 shows an explanatory example where a front portion of the ferrule holder 60 may be shaped to engage a portion of the receptacle 180 (e.g., alignment features of passageway of the receptacle) for course self-alignment before the ferrule 50 engages the complementary device. Additionally, the ferrule holder 60 may include other features that aid in self-alignment of the ferrule 50. For instance, the ferrule holder 60 may have a planar surface 68 on a medial portion that engages a generally flat wall or stop of the optical housing 80 of connector 100. Using planar surface 68 on the medial portion of ferrule holder 60 allows the ferrule holder 60 to easily translate laterally in the X-direction or Y-directions, thereby allowing the ferrule 50 to move in the needed direction accommodate lateral misalignment as the ferrule moves in the Z-direction for mating. Using the flat surfaces is contrary to conventional designs that limit or restrict lateral translations of the ferrule assembly using tapered seats and the like. Further, these concepts may be used with other self-aligning concepts disclosed if desired or not.

[0048] Alternatively, the ferrule holder 60 may cooperate with a retainer 79 for positioning the ferrule holder 60 for inhibiting engagement between the ferrule holder 60 and optical housing 80 of the connector 100 as depicted in FIG. 10. Another concept forallowing self-alignment of ferrules to accommodate lateral misalignment includes providing a lateral clearance between the ferrule holder 60 and housing 80. For instance, the optical housing 80 may include an optical housing passageway 85 at a medial portion that is sized larger than the ferrule holder 60 positioned in the optical housing passageway 85 for providing a lateral clearance for improving translation laterally in the X-direction or Y-direction as the ferrule moves in the Z-direction for mating.

[0049] The disclosed features for improving self-alignment of the ferrule(s) 50 or ferrule assemblies 40 disposed in connectors 100 are discussed in further detail with reference to the explanatory examples. Of course, other variations using the disclosed concepts are also possible.

[0050] Ferrules 50 according to the disclosure comprises a fiber bore 52 extending from a rear end 51 into the body of the ferrule 50 with a suitable optical interface 68 disposed at the front end 53. Optical interface 68 may comprise any suitable optical interface to cooperate with the desired device. By way of explanation and not limitation, the optical interface 68 may be configured for optical mating using physical contact or free-space coupling as desired. Further, the optical interface 68 may comprises a lens if desired. Lens-based configurations of ferrules for connectors may also have the mating interface 68 in physical contact or not as desired. Ferrule 50 may be at least partially disposed in a ferrule holder 60 as a portion of a ferrule assembly 40 such as depicted in FIG. 4 or not as desired. In other variations, the ferrule 50 can be molded or formed as a monolithic component with the ferrule 50 being formed with the ferrule holder 60 according to the concepts disclosed,

[0051] Turning to FIGS. 2A-2F, an explanatory ferrule 50 is shown as it is being inserted into a representative receptacle 180 having a misalignment in the lateral direction for explaining the concepts disclosed herein. For the sake of simplicity, only ferrule 50 is shown in FIGS. 2A-2F for showing the concepts. Ferrule assemblies 60 or connectors 100 disclosed may comprise this explanatory ferrule 50 shown in FIGS. 2A-2F or other ferrules 50 as disclosed herein. Of course, ferrules 50 according to the concepts disclosed may have other suitable geometries at the front portion for use with ferrule assemblies 60 or suitable connectors 100 as desired.

[0052] FIG. 2A shows ferrule 50 having a misalignment between longitudinal axis (LA) of ferrule 50 and the centerline (CL) of the receptacle 180. As depicted, themisalignment between the longitudinal axis (LA) of ferrule 50 and the centerline (CL) of the receptacle 180 is represented by distance (D). Ferrule 50 may comprise a lead-in portion 55 at the front end 53 comprising a ball-shaped portion 57 for inhibiting the binding of the ferrule 50 during insertion into a complementary device if laterally misaligned.

[0053] The ball-shaped portion 57 inhibits the binding of ferrule 50 during insertion into a complementary device if laterally misaligned. The ball-shaped portion 57 is attached near the front end 53 of the ferrule 50. The ball-shaped portion 57 may use any suitable geometry such as being truncated in one or more planes or surfaces so that the ball-shaped portion 57 is only formed as a partial ball-shape adjacent the front end 53 of the ferrule 50. FIG. 2B in the upper right depicts the ferrule 50 approaching the receptacle 180 so that the ball-shaped portion 57 contacts the upper portion of the passageway of the receptacle 180 in a misaligned position.

[0054] FIG. 2C in the middle left depicts the ball-shaped portion 57 of ferrule 50 causing the ferrule to rotate to find and align with the entrance of the passageway of receptacle 180 as the ferrule 50 is inserted further into the passageway of the receptacle 180. This self-aligning of ferrule 50 is aided by the ball-shaped portion 57. Additionally, a reduced size of the dimension of the lead-in portion 55 compared with the dimension of the nominal diameter of the body of the ferrule 50 at a rearward portion for inhibiting binding. By way of explanation, ferrule 50 may vary the diameter at different longitudinal locations along the length of the body of ferrule 50. In this instance, the lead-in portion 55 comprises a lead-in diameter 55D that is smaller than a rearward nominal diameter 52D that is adjacent to the lead-in portion.

[0055] The ball-shaped portion 57 of ferrule 50 may also comprise a smaller diameter 55D compared with the reaward nominal diameter 52D of the body that is rearwardly adjacent to the lead-in portion 55 if desired. This smaller diameter of the ball-shaped portion 57 allows further movement of the ferrule 50 as it engages with the receptacle 180 and inhibits binding if the ferrule 50 is misaligned. For instance, the ball-shaped portion 57 may have diameter 55D that is about 0.05 millimeters or more smaller than the rearward nominal diameter 52D of the body of the ferrule 50.

[0056] Ferrule 50 may have other geometry for inhibiting the binding of the ferrule 50 during insertion into a complementary device such as receptacle 180. As depicted in FIG. 2A, the ferrule 50 comprises a second lead-in portion 56 disposed rearward of the lead-in portion 55 at the front end 53. As shown in FIG. 2D in the middle right, the ferrule 50 continues to advance into the passageway of the receptacle 180 until the second lead-in portion 56 encounters the opening of the passageway of the receptacle 180. The second lead-in portion 56 may allow further insertion of the ferrule 50 into the receptacle while inhibiting binding or damage due to misalignment. Second lead-in portion 56 may have any suitable geometry as desired for improving mating with the complimentary' device.

[0057] As depicted in FIG. 2D, this ferrule 50 has second lead-in portion 56 that comprises an angled surface. For instance, the second lead-in portion 56 may be an angled surface that may resemble a truncated cone that intersects the ball-shaped portion 57 at a suitable location along the body of the ferrule 50. This geometry between the second lead-in portion 56 and the lead-in portion 55 may create a narrower waist that angles outward to the desired diameter moving further rearward from the lead-in portion 55 of the ferrule 50. The waist of ferrule 50 may have a waist diameter WD.

[0058] As shown, this angled surface increases the diameter of the ferrule from the waist diameter WD moving rearward. Further, the angled surface may ride the upper portion of the opening of the passageway of the receptacle 180 as the ferrule 50 is inserted into receptacle 180. Thus, the second lead-in portion 56 further self-aligns the ferrule 50 by pivoting and aligning the ferrule 50 as it is inserted into the passageway of the receptacle 180. FIG. 2E show the ferrule 50 further inserted into the receptacle 180 past the second lead-in portion 56 with the ferrule 50 aligned within the receptacle 180.FIG. 2F shown in the lower right depicts the ferrule 50 fully-inserted into the passageway of the receptacle 180 after being self-aligned by the features of the ferrule 50 during insertion for optical mating.

[0059] Ferrules 50 may comprise other geometries for improving insertion performance if misalignment occurs as well. FIG. 3 depicts another ferrule 50 with the fiber bore 52 extending from the rear end 51 into the ferrule according to the concepts disclosed herein. FIG. 3 depicts the lead-in portion 55 at the front end 53 that comprising a ball-shaped portion 57 for inhibiting the binding of the ferrule 50 duringinsertion or removal into a complementary device if laterally misaligned. Ferrule 50 of FIG. 3 may also comprise a lead-in diameter 55D that is smaller than a rearward nominal diameter 52D of the body rearward of the one or more lead-in portions if desired. The lead-in diameter 55D is defined as the largest cross-sectional dimension taken orthogonal to the longitudinal axis (LA) of the ferrule 50. Other similar dimensions or diameters of ferrule 50 are measured in cross-section in the direction orthogonal to the longitudinal axis (LA) of the ferrule 50 as well.

[0060] The lead-in portion 55 of the ferrule 50 of FIG. 3 may comprises a chamfer 54 disposed forward of the ball-shaped portion 57. The chamfer 54 is disposed at an angle (A) measured from the longitudinal axis (LA) of ferrule 50. Angle (A) may have any suitable value such as between 25 degrees and 45 degrees for improving misalignment performance.

[0061] By way of example and not limitation, ferrule 50 may have a nominal diameter of 1.25 millimeters for the body rearward of the one or more lead-in portions. The lead-in portion 55 at the front end may have ball-shaped portion 57 that is truncated at the front with chamfer 54. Further, ball-shaped portion 57 of ferrule 50 may also comprise a smaller diameter 55D compared with the rearward nominal diameter 52D that is adjacent to the lead-in portion 55 if desired. For instance, the smaller diameter 55D may be about 1.2 millimeters, which is smaller than the nominal diameter 52D of the body rearward of the one or more lead-in portions. The smaller diameter 55D may be located at a length (LI) from the front end 53 of about 0.54 millimeters. The angle (A) for the chamfer 54 may be about 35 degrees, thereby providing the front end 53 with an end face having a diameter of about 0.6 millimeters.

[0062] Ferrules 50 may comprise a second lead-in portion 56 rearward of the lead-in portion 55 on the body of ferrule 50. The ferrule 50 of FIG. 3 also comprises second lead-in portion having an optional waist with a generally flat profile (i.e., a short cylindrical section) having a smaller diameter than the diameter of the adjacent ballshaped portion 57 if desired. By way of example, the waist may intersect the rear side of the ball-shaped portion 57 before transitioning into the remaining length of the second lead-in portion 56. Where the waist and rear side of the ball-shaped portion 57 intersectin FIG. 3, the waist and rear side of the ball-shaped portion 57 may have the same dimension.

[0063] In ferrule 50 of FIG. 3 the waist may have a diameter 57D of about 1 millimeter that matches the rear side dimension of the ball-shaped portion 57. From the waist a second angled portion may extend to the nominal diameter of the body of the ferrule for the second lead-in portion 56. This second angled portion comprises an angle (B) extending from the waist to the nominal diameter 52D of ferrule 50. Angle B may be about 25 degrees, but other angles (B) are also possible as desired. A total lead-in length (L2) for ferrule 50 may comprise the length of the lead-in portion 55 plus the length of the second lead-in portion 56. For instance, the total lead-in length (L2) may be about 1.25 millimeters.

[0064] Although, specific geometry and dimensions were discussed with respect to the explanatory ferrule 50 of FIG. 3 the ferrule concepts may be used with other geometries and / or dimensions as desired. For instance, the nominal diameter 52D of the ferrule 50 may have any suitable size. Likewise, the dimensions of the lead-in portion 55 and second lead-in portion 56 may have other geometries or dimension as desired.

[0065] Receptacle 180 may be a portion of a device instead of being terminated to an end of a cable if desired. By way of explanation and not limitation, receptacle 180 may be a portion of a device comprising an active assembly such as an optical-electrical transceiver for converting and communicating signals. In other applications of the receptacle 180 may include being the receptacle for a high-resolution camera or other sensor. Alternatively, receptacle 180 may be a portion of a passive device such terminating fiber optic cable(s) for making optical connections between cable assemblies for an inline connection.

[0066] The self-aligning concepts disclosed herein may be used with any suitable connector 100. FIGS. 4-10 are schematic sectional representations of connectors 100 showing details of the connectors that may use the concepts disclosed. Still other connectors are possible for the disclosed concepts. By way of example, the disclosed self-alignment concepts may be used with connectors disclosed in: WO2024 / 072432 filed on November 23, 2022 and titled FIBER OPTIC CONNECTORS HAVING AN OUTER HOUSING WITH A LONGITUDINAL OPEN SLOT; US Patent Publication 2024 / 0103229 filed November 30, 2024 and titled FIBER OPTIC CONNECTORSHAVING ONE OR MORE OPTICAL TERMINALS; and US Provisional Application 63 / 701,174 filed on September 30, 2024 and titled CONFIGURABLE HYBRID FIBER OPTIC CONNECTORS all three of which are incorporated herein by reference in their entirety and filed by Corning Research & Development Corporation of Charlotte, North Carolina. Further, connectors 100 disclosed may terminate an optical fiber 92 of a fiber optic cable 90 in ferrule 50 for creating a fiber optic cable assembly 120 such as depicted in FIG. 10.

[0067] FIGS. 4-9 shows an explanatory example of connector 100 having ferrule 50 having a fiber bore 52 that is similar to ferrule 50 of FIG. 3 being aligned and then inserted into a receptacle 180 of complementary device 200 for depicting the selfaligning concepts disclosed. The connector 100 has the ferrule 50 disposed within an optical housing 80 when assembled. As shown in the schematic sectional views, the optical housing 80 of connector 100 is aligned for mating with complementary device 200. During mating, the optical housing 80 enters into a front opening disposed at a front end 203 of a device housing 220 and into a housing passageway 202 of the complementary device 200 as depicted in FIGS. 5-9.

[0068] Connector 100 has ferrule 50 that is a portion of ferrule assembly 40 that includes ferrule holder 60, As depicted, a front portion 63 of the ferrule holder 60 comprises a suitable shape for engaging a passageway entrance 205 of complementary device 200 that leads to receptacle 180 that receives ferrule 50 when mated. The front end 63 of ferrule holder 60 aides the self-alignment of the ferrule 50 before the ferrule 50 engages the passageway 183 of the receptacle 180 of the complementary device 200. Thus, the shape of the front end 63 of ferrule holder 60 comprises self-alignment features that cooperate with the passageway entrance 205 of the device 200 during mating. These features on the front end 63 of the ferrule holder 60 may be used with ferrules 50 according to the disclose or alternatively with conventional ferrules having a cylindrical front end with a chamfer as desired. Likewise, the passageway entrance 205 with the self-aligning features on device 200 may be used with conventional ferrules as well.

[0069] More specifically, FIG. 4 depicts a schematic sectional view of connector 100 with the optical housing 80 aligned for mating with complementary device 200. Opticalhousing 80 comprises a passageway 82 extending from a rear end 81 to a front end 83. A medial portion of optical housing 80 comprises a wall having an optical housing passageway 85 therethrough for receiving a portion of the ferrule assembly 40 therethrough. The wall of the optical housing 80 provides a forward stop for the ferrule holder 60 (and ferrule) that is biased to a forward position within the connector by an optional resilient member 67. Although connector 100 is depicted with resilient member 77, other connectors may omit the resilient member 77 depending on the design.

[0070] The optical housing passageway 85 allows a portion of the ferrule 50 and / or ferrule assembly 40 to pass therethrough and may be sized for allowing the translation of the ferrule 50 and / or ferrule assembly 40 in the X-direction or Y-direction as a selfalignment feature. In other words, the optical housing passageway 85 may be oversized with respect to a ferrule dimension or ferrule holder dimension positioned adjacent to the optical housing passageway 85 when assembled. For instance, the optical housing passageway 85 may have a passageway diameter 85D that is at least 1.25 times larger than the portion of the rearward nominal diameter 52D of the ferrule 50 adjacent to the passageway diameter 85D. In other variations, the optical housing passageway 85 may have a passageway diameter 85D that is at least 1.25 times larger than the portion of the ferrule assembly 40 that is located adjacent to the passageway diameter when assembled. The passageway diameter 85D may be 1.5 times or 2 times greater than the portion of the ferrule 50 or ferrule assembly 40 adjacent thereto when assembled.

[0071] The ferrule 50 or ferrule assembly 40 used with connector 100 may include features disclosed herein that aid in the self-alignment of the ferrule or ferrule assembly during mating of connector 100 as disclosed herein. By way of explanation, the ferrule holder 60 may comprise a medial portion 65 disposed between the front end 63 and rear end 61 that comprises a planar surface 48. Although described as a planar surface the concepts may use other shapes for reducing surface area contact and / or friction such as cupped or the like for allowing translation in the X- and Y-directions. The planar surface 68 of the medial portion 65 faces in the forward-direction when assembled into the optical housing 80 of connector 100 such as shown in FIGS. 4-9. For instance, the planar surface 68 may be disposed on a flange of the ferrule holder 40, thereby providing a surface that allows the ferrule 50 or ferrule assembly 60 to translate in the X-direction or Y-direction with respect to the optical housing 80 when a self-aligning force may beapplied for aligning the ferrule 50 within the receptacle 180 during mating. In other variations, the ferrule 50 may be molded or formed with the planar surface 68 for operating in a similar manner for translating in the X-direction or Y-direction with respect to the optical housing 80 when a self-aligning force may be applied.

[0072] Likewise, the wall portion of the optical housing 80 that faces rearward and opposes the planar surface 68 of the ferrule 50 or ferrule holder 40 may include a housing stop surface 88. The housing stop surface 88 may have any suitable shape such as planar, but other surfaces such as concave or convex are possible. The housing stop surface 88 may cooperate with planar surface 68 for promoting translation in the X-direction or Y-direction with respect to the optical housing 80 without sticking or binding between surfaces 68,88 during mating or unmating. These surfaces 68,88 may be used in combination with one or more other self-aligning features disclosed herein or be used without the other self-aligning features as desired for the connector design. Allowing larger offsets of the ferrule or ferrule assembly with respect to the optical housing may also benefit from other structures or geometries that aid in self-alignment for mating and unmating and inhibit binding or damage.

[0073] By way of example, the planar surfaces of the connector 100 may also be used in combination with a suitable shape on the passageway entrance 205 that leads to receptacle 180 of complementary device 200 and cooperate with the shape on the front end 63 of the ferrule holder 60. Consequently, the ferrule 50 self-aligns using the front end 63 of the ferrule holder 60 that rides on the passageway entrance 205 before the ferrule 50 reaches the receptacle 180 during mating. This combination may be use with ferrules 50 disclosed herein or conventional ferrules as desired. Consequently, the contact interface between various structures of the ferrule 50 or ferrule assembly 40 can be designed for allowing suitable translations in the X-direction or Y-direction when selfaligning forces are present and may cooperate with features on the complementary device as well during mating and unmating.

[0074] FIG. 5 depicts the front end 83 of optical housing 80 entering the front opening disposed at the front end 203 of a device housing 220 and into a housing passageway 202 of the complementary device 200. The cooperation of optical housing80 and the passageway 202 of the complementary device provide gross alignment during insertion and positions the respective components for mating. Features on optical housing 80 and / or features on the passageway 202 aid in the prepositioning and alignment for mating.

[0075] FIG. 6 shows the further insertion of the connector 100 into the passageway 202 of the complementary device 200. As depicted, the front portion 63 of the ferrule holder 60 comprises a suitable shape for engaging a passageway entrance 205 of complementary device 200 that leads to receptacle 180 that receives ferrule 50 when mated. The front end 63 of ferrule holder 60 aides the self-alignment of the ferrule 50 before the ferrule 50 engages the passageway 183 of the receptacle 180 of the complementary device 200. As shown, the front end 63 of ferrule holder 60 may have a chamfered or ball-shaped portion that may contact or ride on the passageway entrance 205 of the complementary device 200 if misalignment occurs. FIG. 7 depicts the front end 63 of ferrule holder 60 being guided by the self-alignment with the front end 63 passing by or engaging the passageway entrance 205 as the connector 100 is inserted for mating.

[0076] FIG. 8 depicts the front end 53 of the ferrule 50 entering the receptacle 180 as the connector 100 is further inserted into the complementary device. The self-aligning of the ferrule 50 may occur in a manner similar to that shown and described with respect to FIGS. 2A-2F if misalignment is present. FIG. 9 shows connector 100 fully-inserted into the complementary device 200 in a mated state.

[0077] Still other variations of the concepts for connectors 100 are possible. Illustratively, FIG. 10 is a schematic cross-sectional representation of another connector 100 that includes a ferrule 50 comprising one or more lead-in portions 55,56 according to the concepts disclosed. As depicted, ferrule 50 is secured to ferrule holder 60 for forming ferrule assembly 40, but the ferrule 50 could be monolithically formed as discussed herein. Connector 100 of FIG. 10 is similar to connector 100 of FIGS. 4-9, but has a different construction for retaining or securing the ferrule assembly 40 within the optical housing 80 when connector 100 is assembled. The ferrule assembly still cooperates with the medial portion of the optical housing 80 by engaging a generally flat wall or stop of the optical housing 80; however, it does not use a flange of the ferrule holder 60 like other designs.

[0078] Instead, connector 100 of FIG. 10 comprises a retaining member 79 for securing assembling the ferrule assembly 40 in connector 100 and allowing suitable translations of the ferrule 50 or ferrule assembly in the X-direction or Y-direction when self-aligning forces are present. Retaining member 79 may be a component that cooperates with the ferrule holder 60 for keeping the ferrule holder 60 from being pushed outward from the optical housing 80. The retaining member 79 may be sized to be larger than the optical housing passageway 85 at the wall of optical housing 80 so it may not pass through the optical housing passageway 85. By way of example, the retaining member 79 may be a clip that fits into a groove of the ferrule holder 60 an acts as a forward stop for the ferrule assembly 40. Like other connectors 100, the optical housing passageway 85 may be sized to be sufficiently larger than the portion of the ferrule holder 60 that is disposed through the optical housing passageway 85 for allowing suitable movement in the X-direction or Y-direction for accommodating misalignment of ferrule 50 with complimentary device 200. Additionally, the retaining member 79 may be configured with a planar surface for cooperating with the housing stop surface 88 of the rear side of the wall of the optical housing 80, thereby promoting translation in the X-direction or Y-direction with respect to the optical housing 80 without sticking or binding between the retaining member 79 and the housing stop surface 88 during mating or unmating. This embodiment depicts the retaining member 79 adjacent the rear end 41 of ferrule assembly 40, but the retaining member 79 could be secured at other locations of the ferrule assembly 40 as well. Additionally, the concepts using retaining member 79 may be used with other concepts disclose herein as desired or not.

[0079] FIG. 11 is a partial sectional view of the front end of another terminated connector 100 similar to the connector 100 of FIG. 10. Connector 100 may use any of the ferrule holders 60 or ferrules 50 disclosed herein with the concepts of retaining member 79. Specifically, connector 100 illustrated includes a ferrule 50 comprising one or more lead-in portions 55 and uses retaining member 79 for securing the ferrule assembly 40 in connector 100 and allowing suitable translations of the ferrule 50 or ferrule assembly in the X-direction or Y-direction for self-aligning the ferrule assemblies 60 and inhibiting excessive forces on the complimentary device 200 during opticalmating. Each resilient member 77 member biases the respective ferrule assembly 60 to a forward position so that the retaining member 79 abuts against the housing stop surface 88 as shown while still allowing translation of the ferrule assembly 60. The optical housing 80 is partially disposed within a connector housing 150 so that the front end 83 of the optical housing 80 extends beyond the connector housing 150.

[0080] In this connector 100 the retaining member 79 is configured as a generally planar clip that cooperates with the ferrule holder 60 that acts as the forward stop for the ferrule holder 60 from being pushed outward from the optical housing 80 beyond the desired Z-direction. Specifically, a portion of the retaining member 79 fits into a groove (not numbered) formed adjacent to the rear end 61 of the ferrule holder 60. The clip may have any suitable arrangement such as a C-clip and E-clip that fits into a groove of the ferrule assembly 60. Other suitable retaining members 79 may be used such as washers or the like may be used as desired.

[0081] The retaining member 79 is sized to be larger than the optical housing passageway 85 at the wall of optical housing 80 so it may not pass any further relative to the optical housing passageway 85. The optical housing passageway 85 is sized sufficiently larger in diameter than the portion of the ferrule holder 60 that is disposed through the optical housing passageway 85, thereby allowing suitable movement in the X-direction or Y-direction of the ferrule assembly 60 relative to the optical housing 80 for accommodating misalignment of ferrule 50 with complimentary device 200. The planar surface of the retaining member 79 cooperates with the surface at the rear side of the wall of the optical housing 80, thereby allowing translation in the X-direction or Y-direction within the oversized optical housing passageway 85 during mating or unmating. The Consequently, the lead-in portion 55 and / or the front end 63 of ferrule holder 60 may contact or ride on respective surfaces such the 183 or passageway entrance 205 for self-aligning with the complementary device 200 if misalignment occurs.

[0082] Additionally, if connector 100 using the concepts disclosed are a duplex connector having two ferrule holders 60 for two separate optical channels, then the two ferrule holders 60 may translate independently from each other for self-aligning to the complementary device 200 and reducing insertion forces on the complementary device 200.

[0083] FIG. 11 shows further details of the front end of the assembled connector 100 with the optical housing 80 attached to the connector body 150. FIG 12 shows a bottom perspective view of connector 100 showing the connector body 150 having a longitudinal open slot 150S. The longitudinal open slot 150S extends from a front end 153 to a rear end 155 of the connector body 150. A protrusion 140 of the optical housing 80 is suitable for cooperating with the longitudinal open slot 150S for securing the connector body 150 to the optical housing 80.

[0084] FIG. 12 shows the cooperation of the longitudinal open slot 150S of the connector body 150 and the protrusion 149 formed on the optical housing 80, As depicted, the optical housing 80 has protrusion 149 with a wedge-shape that cooperates with being received in the longitudinal open slot 150S of connector body 150. By way of explanation, connector body 150 may comprise one or more latch features 159 extending inward toward the longitudinal open slot 150S configured for engaging a protrusion 149 disposed on the optical housing 80. Latch features 159 may cooperate with the geometry of the protrusion 149 as desired for retention of the connector body 150 when assembled. Latch features 159 of connector body 150 or protrusion 149 of optical housing 80 may have any suitable geometry for allowing assembly or removal from the connector body 80 in a suitable fashion.

[0085] By way of example, the protrusion 149 of optical housing 80 may comprise a front end that is wider than a rear end (i.e., a wedge shape), but other geometries are possible for the protrusion. In this instance, protrusion 149 has front end configured as a flat surface and rear end configured to converge to a smaller portion. For instance, the rear end may converge to a truncated end or to a point that is narrower that the front end as depicted in FIG. 12. The latch features 159 may engage part of the flat surfaces of the protrusion 149.

[0086] As depicted, latch features 159 disposed on connector body 150 cooperate with the optical housing 80 for assembly. For instance, latch features 159 of connector body 150 cooperate with the protrusion 149 of optical housing 80 for positioning during assembly. Specifically, the front end of protrusion 149 aids in the positioning and insertion of the optical housing 80 into the connector body 150. Protrusion 149 may alsoinclude lead-in portions (i.e., angled surfaces) if desired for aiding in the installation of the connector body 150. The lead-in portions of protrusion 149 depicted are angle surfaces that act as ramps for aligning and flexing open the connector body 150 for easier assembly. Further, protrusion 149 may cooperate with latch features 159 on the connector body 150 for securing the optical housing 80 to connector body 150. The geometry' may also allow removal of the optical housing 80 from the hybrid connector body 150.

[0087] Of course, other shapes and arrangements are possible for the protrusion 149 of optical housing 80 and cooperating latch features on the connector body 150 of connector 100. By way of example, the connector body 150 can have an opening with the front portion that is larger than the rear portion of the connector body 150 if desired. Further, the longitudinal open slot 150S of the connector body 150 may have a width that varies at different locations between the front end 153 and rear end 155. By way of example, and not limitation, a first slot width 150SW1 may be larger than a second slot width 150SW2 for the connector body 150 as desired. As depicted, the slot width at the forward portion of the connector body 150 may be sized for cooperating with a portion of the housing 80 for connector 100.

[0088] Connectors 100 disclosed herein may have still further advantageous features. As shown in FIG. 12, connector 100 may comprise one or more keys for inhibiting optical mating with a non-compliant connector or device. As shown, optical housing 80 may comprise one or more keying portions 147 formed therein that are configured to cooperate with the counterpart features on complimentary' device for limiting the optical mating of connector 100 to a suitable device.

[0089] The keying portion 147 of connector may be disposed at any suitable location on the connector 100 and have a desired profile (i.e., male or female with the desired shape) for allowing mating with a compliant connection or device. As depicted, keying portion 147 is a protruding key having a shape with a width, a height and a location for being received within a complimentary keyway of the complementary mating device that is appropriately sized and shaped as may be desired. Variations in keying may include changing the width, the height and / or the location of the key on connector 100 for making distinct mating profiles for connector 100. Consequently, a wiring assembly or harness end could have two or more connectors 100 disposed on an end of the assembly witheach connector 100 having a distinct keying profile adapted for mating with a distinct counterpart device so that the connectors of the wiring assembly or harness only mate in the desired orientation with the counterpart assembly for eliminating errors in initial installation and any subsequent service.

[0090] Other variations of connector body 150 are possible for the use with the optical housing 80 for creating alternate connectors 100 as well. Illustratively, FIG. 13 is a partially exploded view depicting an explanatory connector 100 suitable for both optical mating and electrical connection using the concepts disclosed, thereby providing a hybrid connector. This connector 100 is similar to the other connectors and may use any of the disclosed features for self-alignment of the ferrules 50 or ferrule assemblies 60 disposed within optical housing 80. As depicted, this connector body 150 further comprises first and second electrical passageways 157 configured for receiving respective electrical terminals 98 that terminate electrical conductors 90E for power and / or communication as may be desired.

[0091] This connector body 150 configured for hybrid connectivity is similar to the connector body 150 of FIGS. 11 and 12 FIG. 13 shows that the connector body 150 also has a latching trigger 152 integrally formed on a first side of the connector body 150. The latching trigger 152 allows the unmating of hybrid connector 100 from the complementary' device by being suitably pushed inward toward the connector body 150 to raise a latching tab (not visible) disposed on the forward side. Like before, the latching trigger 152 is disposed adjacent a rear end 155 and the forward end comprises the latching tab 158 for cooperating with a latching lug 254 disposed on the housing 250 of hybrid connector 200 as best shown in FIG. 11 Once the latching trigger 152 is suitably pushed downward then, the technician can unmate the connector 100 by pulling in the rearward direction on connector 100. The latching tab also advantageously aids in maintaining a secure mating of connector 100.

[0092] Additionally, this connector body 150 may also comprise a longitudinal open slot 150S extending from a front end 153 to a rear end 155. The longitudinal open slot 150S may extend from an outer surface into the hybrid connector body 150, The longitudinal open slot 150S is in communication with the passageway 156 of connectorbody 150. The longitudinal open slot 150S extends into the connector body 150 and interrupts the circumferential hoop so that the bottom portion of connector body 150 is furcated into a first side and a second side that is divided by the longitudinal open slot 150S like the connector body of FIGS. 11 and 12.

[0093] Consequently, a portion of the optical housing 80 may cooperate with a portion of the longitudinal open slot 150S like the optical housing 80 of FIGS. 11 and 12. This allows the quick and reliable assembly of the optical housing 80 to the connector body 150. Specifically, the optical fiber or cable is thread into the longitudinal open slot 150S and into the passageway 156 of the connector body 150 for assembly. Then, the optical housing 80 may be assembled by seating the optical housing 80 in the connector body 150. This construction also allows for the removal of the optical housing 80 from the connector body 150 as may be needed or desired. Further, the connector body 150 may align and engage a portion of the optical housing 80 for securing the optical housing 80 to the connector body 150 for quick and easy assembly. For instance, the optical housing 80 may have a geometric feature formed for securing the optical housing at the desired position in the longitudinal open slot 150S. The furcation of the lower portion of the connector body 150 allows flexing of the connector body 150 so that the optical housing 140 and hybrid connector body 150 can cooperate for assembly.

[0094] Other configurations of optical housings and connector bodies may be used with the concepts disclosed for providing connectors with self-aligning females or ferrule assemblies as desired.

[0095] Although the disclosure has been illustrated and described herein with reference to explanatory embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples can perform similar functions and / or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the disclosure and are intended to be covered by the appended claims. It will also be apparent to those skilled in the art that various modifications and variations can be made to the concepts disclosed without departing from the spirit and scope of the same. Thus, it is intended that the present application cover the modifications and variations provided they come within the scope of the appended claims and their equivalents.

Claims

We claim:

1. A fiber optic connector (100) comprising:a ferrule (50) comprising a fiber bore (52) extending from a rear end (51) into the ferrule (50) and an optical interface (58) disposed at a front end (53) of the ferrule (50), wherein the ferrule (50) comprises a lead-in portion (55) at the front end (53) comprising a ball-shaped portion (57) for inhibiting the binding of the ferrule (50) during insertion into a complementary device if laterally misaligned; andan optical housing (80) comprising a passageway (82) extending from a front end (81) to a rear end (83), wherein the ferrule (50) is configured to be disposed within the optical housing (80) when assembled.

2. The fiber optic connector of claim 1, wherein the lead-in portion (55) comprises a lead-in diameter (55D) that is smaller than a rearward nominal diameter (52D) of the ferrule (50).

3. The fiber optic connector of claims 1 or 2, the ferrule (50) further comprising a second lead-in portion (56) disposed rearward of the lead-in portion (55 ).

4. The fiber optic connector of claim 3, wherein the second lead-in portion (56) comprises angled surface.

5. The fiber optic connector of claim 2, wherein the rearward nominal diameter (52D) of the ferrule (50) is 1.25 millimeters.

6. The fiber optic connector of any one of claims 1-5, wherein the ferrule (50) is a portion of a ferrule assembly (40) that comprises a planar surface (68) at a medial portion of the ferrule assembly (40).

7. The fiber optic connector of any one of claims 1-6, wherein the optical housing (80) comprises an optical housing passageway (85) configured for receiving a portion of the ferrule (50) when assembled, wherein the optical housing passageway (85)has a passageway diameter (85D) that is at least 1.25 times larger than the portion of the ferrule (50) passing through the optical housing passageway (85).

8. The fiber optic connector of any one of claims 1-7, further comprising a second ferrule (50) comprising a second fiber bore (52) extending from a respective rear end (51) into the second ferrule (50), wherein the second ferrule (50) is configured to be disposed within the optical housing (80) when assembled.

9. The fiber optic connector of any one of claims 1-8, further comprising a connector body (150) having a longitudinal open slot (150S) and the connector body (150) is configured for receiving a portion of the optical housing (80).

10. The fiber optic connector of claim 9, the connector body (150) further comprising one or more latching features (159) extending inward toward the longitudinal open slot (150S) and configured for engaging a protrusion (149) disposed on the optical housing (80).

11. The fiber optic connector of any one of claims 1-10, further comprising a spring (67) for biasing the ferrule (50) to a forward position when the fiber optic connector (100) is assembled.

12. The fiber optic connector of claim 11, further comprising a spring push (76) configured as a backstop for the spring (67).

13. The fiber optic connector of any one of claims 1-12, further comprising a connector position assurance (CPA) that cooperates with a latching trigger (152) and is configured for inhibiting the latching trigger (152) from being depressed.

14. The fiber optic connector of any one of claims 1-13, wherein the ferrule (50) is a portion of a ferrule assembly (60) that further comprises a ferrule holder (40).

15. The fiber optic connector of any one of claims 1-14, wherein the fiber optic connector (100) is a portion of a cable assembly (120).

16. A fiber optic connector (100) comprising:a ferrule (50) comprising a fiber bore (52) extending from a rear end (51) into the ferrule (50), and an optical interface (58) disposed at a front end (53) of the ferrule (50), wherein the ferrule (50) comprises a lead-in portion (55) at the front end (53) comprising a ball-shaped portion (57) and the lead-in portion (55) comprises a lead-in diameter (55D) that is smaller than a rearward nominal diameter (52D) of the ferrule (50) for inhibiting the binding of the ferrule (50) during insertion into a complementary device if laterally misaligned; andan optical housing (80) comprising a passageway (82) extending from a front end (81) to a rear end (83), wherein the ferrule (50) is configured to be disposed within the optical housing (80) when assembled.

17. The fiber optic connector of claim 16, the ferrule (50) further comprising a second lead-in portion (56) comprising an angled surface that is disposed rearward of the lead-in portion (55).

18. The fiber optic connector of claims 16 or 17, wherein the rearward nominal diameter (52D) of the ferrule (50) is 1.25 millimeters.

19. The fiber optic connector of any one of claims 16-18, further comprising a second ferrule (50) comprising a second fiber bore (52) extending from a rear end (51) into the second ferrule (50), wherein the second ferrule (50) is configured to be disposed within the optical housing (80) when assembled.

20. The fiber optic connector of any one of claims 16-19, further comprising a connector body (150) having a longitudinal open slot (150S) and the connector body (150) is configured for receiving a portion of the optical housing (80).

21. The fiber optic connector of claim 20, the connector body (150) further comprising one or more latching features (159) extending inward toward the longitudinalopen slot (150S) and configured for engaging a protrusion (149) disposed on the optical housing (80).

22. The fiber optic connector of any one of claims 16-21, further comprising a spring (67) for biasing the ferrule (50) to a forward position when the fiber optic connector is assembled.

23. The fiber optic connector of claim 22, further comprising a spring push (76) configured as a backstop for the spring (67).

24. The fiber optic connector of any one of claims 16-23, further comprising a connector position assurance (CPA) that cooperates with a latching trigger (152) and is configured for inhibiting a latching trigger (152) from being depressed.

25. The fiber optic connector of any one of claims 16-24, wherein the ferrule (50) is a portion of a ferrule assembly (60) that further comprises a ferrule holder (40).

26. The fiber optic connector of any one of claims 16-25, wherein the fiber optic connector is a portion of a cable assembly (120).

27. A ferrule (50) comprising a fiber bore (62) extending from a rear end (51) into a body of the ferrule (50), and a front end (53) of the ferrule (50) comprising a lead-in portion (55) comprising a ball-shaped portion (57) for inhibiting the binding of the ferrule (50) during insertion into a complementary device if laterally misaligned.

28. The ferrule of claim 27, wherein the lead-in portion (55) comprises a lead-in diameter (55D) that is smaller than a rearward nominal diameter (52D) of the ferrule (50).

29. The ferrule of claims 27 or 28, further comprising a second lead-in portion (56) disposed rearward of the lead-in portion (55).

30. The ferrule of claim 29, wherein the second lead-in portion (56) comprises an angled surface.

31. The ferrule of any one of claims 27-30, wherein the ferrule (50) is a portion of a ferrule assembly (40) that comprises a planar surface (68) at a medial portion configured for allowing lateral movement of the ferrule assembly (40).

32. The ferrule of any one of claims 27-31, the ferrule (50) being a portion of a fiber optic connector (100) when assembled.

33. The fiber optic connector of claim 32, wherein the ferrule (50) is a portion of a ferrule assembly (60) that further comprises a ferrule holder (40).

34. A ferrule assembly (40) comprising a fiber bore (52) extending from a rear end (41) into the ferrule assembly (40) and an optical interface (68) disposed at a front end (53) of the ferrule assembly (40), wherein the ferrule assembly (40) comprises a lead-in portion (55) at the front end (53) comprising a ball-shaped portion (57) for inhibiting the binding of the ferrule assembly (40) during insertion into a complementary device if laterally misaligned.

35. The ferrule assembly of claim 34, wherein the lead-in portion (55) comprises a lead-in diameter (55D) that is smaller than a rearward nominal diameter (52D) of a ferrule (50).

36. The ferrule assembly of claims 34 or 35, further comprising a second lead-in portion (56) disposed rearward of the lead-in portion (55).

37. The ferrule assembly of claim 36, wherein the second lead-in portion (56) comprises an angled surface.

38. The ferrule assembly of any one of claims 34-37, wherein the ferrule assembly (40) comprises a planar surface (68) at a medial portion configured for allowinglateral movement of the ferrule assembly (40) when assembled in a fiber optic connector (100).

39. The ferrule assembly of any one of claims 34-38, wherein the ferrule assembly (40) further comprises a ferrule holder (60).

40. The ferrule assembly of any one of claims 34-39, the first ferrule assembly (40) being a portion of a fiber optic connector (100) when assembled,41. A fiber optic connector (100) comprising:a ferrule assembly (40) comprising a ferrule (50) having a fiber bore (52) extending from a rear end (51) into the ferrule assembly (40) and an optical interface (58) disposed at a front end (53) of the ferrule (50); andan optical housing (80) comprising a passageway (82) extending from a front end (83) to a rear end (81), and optical housing (80) comprises an optical housing passageway (85) configured for receiving a portion of the ferrule assembly (40) when assembled, wherein the optical housing passageway (85) has a passageway diameter (85D) that is at least 1.25 times larger than a portion of the ferrule assembly (40) that is disposed through the optical housing passageway (85) adjacent to the optical housing passageway (85) when assembled.

42. The fiber optic connector of claim 41, wherein the ferrule (50) comprises a lead-in portion (55) at the front end (53) comprising a ball-shaped portion (57).

43. The fiber optic connector of claim 42, wherein the lead-in portion (55) comprises a lead-in diameter (55D) that is smaller than a rearward nominal diameter (52D) of the ferrule (50).

44. The fiber optic connector of claims 42 or 43, the ferrule (50) further comprising a second lead-in porti on (56) disposed rearward of the lead-in portion (55).

45. The fiber optic connector of claim 44, wherein the second lead-in portion (56) comprises angled surface.

46. The fiber optic connector of any one of claims 41-45, further comprising a retention member (79) that cooperates with the ferrule assembly (40).

47. The fiber optic connector of claim 46, wherein the retention member (79) fits into a groove of the ferrule assembly (40).

48. The fiber optic connector of any one of claims 41-47, wherein the ferrule assembly (40) comprises a planar surface (68) at a medial portion configured for allowing lateral movement of the ferrule assembly (40) relative to the optical housing (80) when assembled in the fiber optic connector (100).

49. The fiber optic connector of any one of claims 41-48, further comprising a second ferrule (50) comprising a second fiber bore (52) extending from a respective rear end (51) into the second ferrule (50), wherein the second ferrule (50) is configured to be disposed within the optical housing (80) when assembled.

50. The fiber optic connector of any one of claims 41-49, further comprising a connector body (150) having a longitudinal open slot (150S) and the connector body (150) is configured for receiving a portion of the optical housing (80).

51. The fiber optic connector of claim 50, the connector body (150) further comprising one or more latching features (159) extending inward toward the longitudinal open slot (150S) and configured for engaging a protrusion (149) disposed on the optical housing (80).

52. The fiber optic connector of any one of claims 41-51, further comprising a spring (67) for biasing the ferrule assembly (40) to a forward position when the fiber optic connector (100) is assembled.

53. The fiber optic connector of claim 52, further comprising a spring push (76) configured as a backstop for the spring (67).

54. The fiber optic connector of any one of claims 41-53, further comprising a connector position assurance (CPA) that cooperates with a latching trigger (152) and is configured for inhibiting the latching trigger (152) from being depressed.

55. The fiber optic connector of any one of claims 41-54, wherein the fiber optic connector (100) is a portion of a cable assembly (120).

Images