Stackable packaging tray for fiber optic components

Abstract

A packaging tray configured to transport and store fiber optic components has a base and a cover to keep the fiber optic components within their individual compartments. Each packaging tray may receive another packaging tray or be connected to another packaging tray. Each of the packaging trays have latches to attach to beams on the other of the packaging trays thereby connecting the trays to one another.

Description

USCO-195-INTSTACKABLE PACKAGING TRAY FOR FIBER OPTIC COMPONENTSReference to Related Case

[0001] This application claims priority under 35 U.S.C. § 119 (e) to U.S. provisional application no. 63 / 777,975 filed on March 26, 2025, the contents of which are hereby incorporated by reference in their entirety.BACKGROUND OF THE INVENTION

[0002] In the fiber optic connector industry, various components of the fiber optic connector are manufactured in one or more locations and then shipped to several different locations for assembly. The assembled connectors may then be shipped again to an end customer location. Prior to the initial shipping, these components are placed manually in a traditional packaging box with appropriate storage compartments such as the one shown in Fig. 1. This manual packaging is time consuming and, is also, prone to accidental disassembly of the box (e.g., a lid thereof coming off a base) during shipping and handling, despite a latch being provided. Currently, the shipper may put a rubber band around the box and the lid as an additional securing mechanism, which adds to labor and material costs but is still prone to the aforementioned issues (e.g., the rubber band breaking). Since the current base and the lid nest into each other, with no barrier between the base and the lid, the weight of the packaging trays positioned on top of each other can be transferred to the ferrules potentially increasing the chances of damage thereto.

[0003] Growing demands of fiber optic components, including the latest TMT ferrule, have led to a need for automation in packaging of these components for faster packaging and more secure shipping. The lid of the conventional packaging box slides on and off for attachment and detachment, respectively. See Figs. 1& 2. Such a sliding mechanism is hard to automate using robotics due to the orientation and precision required. The conventional packaging box also does not lock or stack together with additional boxes in all degrees of freedom, which is another issue during shipping and challenging for automation.SUMMARY OF THE INVENTION

[0004] According to one aspect, the present invention is directed to a packaging tray for fiber optic components that includes a lid having an opening; and a base having a plurality of compartments to respectively receive fiber optic components, and having a lidUSCO-195-INTremoval latch with a free end positioned in the opening of the lid to secure the lid to the base, and wherein upon a full engagement of the lid to the base, the lid is prevented from removal from the base by the lid removal latch, wherein the plurality of compartments and the lid are surrounded on three sides by walls of the base, a fourth side of the base being open to allow the lid to be removed upon a depression of the lid removal latch, and wherein the base has a base underside to receive an additional packaging tray.

[0005] In some embodiments, the plurality of compartments are each sized to receive a multi-fiber ferrule.

[0006] In some embodiments, the base underside is surrounded by side walls of the base, at least one side wall having at least one stacking latch to receive a beam from an additional base to stack the additional packaging tray to the packaging tray.

[0007] In some embodiments, the base further comprises a side projection on a side wall of the base, the side projection extending outward from the at least one stacking latch and away from the side wall, and a beam above the stacking latch to engage a base of the additional packaging tray identical to the packaging tray thereby stacking the packaging tray in a secure arrangement with the additional packaging tray.

[0008] In some embodiments, the fiber optic components are TMT ferrules trapped in respective ones of the plurality of compartments upon the full engagement of the lid to the base.

[0009] In some embodiments, there is a separation gap between two adjacent ones of the plurality of compartments.

[0010] In some embodiments, the lid includes at least one downward projection from an underside of the lid, the at least one downward projection being an elongated structure extending parallel to an edge of the lid.

[0011] In some embodiments, the at least one downward projection on the lid includes two downward projections and the opening in the lid is located between the two downward projections.

[0012] In some embodiments, the lid removal latch is at a non-zero angle to the lid.

[0013] In some embodiments, the lid removal latch is joined to the base underside.

[0014] In some embodiments, the base also includes a plurality of lid latches each having a chamfer facing away from the lid and a downward facing surface to engage the lid during an attachment of the lid to the base.USCO-195-INT

[0015] In some embodiments, the at least one downward projection is received in at least one groove of the base and the free end of the lid removal latch of the base is received in the opening in the lid.

[0016] In yet another aspect, there is a packaging tray for fiber optic components that includes a lid and a base having a plurality of compartments to respectively receive fiber optic components and coupled to the lid, wherein upon a full engagement of the lid to the base, the lid is prevented from removal from the base, wherein the plurality of compartments and the lid are surrounded on three sides by walls of the base, a fourth side of the base being open to allow the lid to be removed from the base, and wherein the base has a base underside surrounded by side walls of the base to receive an additional packaging tray to form a stacked configuration of a plurality of packaging trays, at least one side wall having at least one stacking latch with an upward facing surface to receive a beam from another packaging tray.

[0017] In some embodiments, the lid has an opening, and the base has a lid removal latch with a free end positioned in the opening of the lid to secure the lid to the base and to release the lid from the base by a depression action of the free end.

[0018] In some embodiments, the lid includes at least one downward projection from an underside of the lid and received in at least one groove of the base, the at least one downward projection being an elongated structure extending parallel to an edge of the lid, the free end of the lid removal latch of the base is received in the opening in the lid, and wherein the base also includes a plurality of lid latches each having a chamfer facing away from the lid and a downward facing surface to engage the lid during an attachment of the lid to the base.

[0019] It is to be understood that both the foregoing general description and the following detailed description of the present embodiments of the invention are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments of the invention and, together with the description, explain the principles and operations of the invention.BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Fig. 1 is a perspective view of a conventional packaging tray;USCO-195-INT

[0021] Fig. 2 is perspective, view of the conventional packaging tray in Fig. 1 with the lid removed;

[0022] Fig. 3 is a perspective view from the rear left of one embodiment of a packaging tray with a lid fully engaged to a base of the packaging tray according to the present invention;

[0023] Fig. 4 is a left rear perspective view of the packaging tray in the Fig. 3 with the lid removed;

[0024] Fig. 5 is a perspective view of a base underside of the packaging tray in Fig.3;

[0025] Fig. 6 is a plan view of the underside of the packaging tray in Fig. 3;

[0026] Fig. 7 is a left rear perspective view of the packaging tray in the Fig. 3 with the lid missing;

[0027] Fig. 8 is a detailed view of the compartments for the fiber optic components;

[0028] Fig. 9 is a cross-sectional view of a portion of the base of the packaging tray in Fig. 3;

[0029] Fig. 10 is a cross-sectional view of a portion of the base of the packaging tray in Fig. 3 with the lid in place;

[0030] Fig. 11 is an elevational view of a cross section view of the packaging tray in Fig. 3; and

[0031] Fig. 12 is a detailed view of the base of the packaging tray in Fig. 3 with lidremoval latch;

[0032] Fig. 13 is a perspective view of the front left portion of the underside of packaging ;

[0033] Fig. 14 is a perspective view from the bottom left of two packaging trays of Fig. 3 connected together;

[0034] Fig. 15 is a perspective view from the upper left of the of two packaging trays ofFig. 14;

[0035] Fig. 16 an elevational view of a cross section of the connected or stacked packaging trays in Fig. 14;

[0036] Fig. 16A is a detailed view of a portion of the cross-section ofFig. 16;

[0037] Fig. 16B is a partial cross section of the connected or stacked packaging trays in Fig. 14 through the window portion of the packaging trays;USCO-195-INT

[0038] Fig. 17 is a perspective view of another embodiment of a packaging tray according to the present invention.DETAILED DESCRIPTION OF THE INVENTION

[0039] Reference will now be made in detail to the present preferred embodiment(s) of the invention, examples of which are illustrated in the accompanying drawings.Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.

[0040] Illustrated in Figs. 1 and 2 is one embodiment of a conventional packaging tray 10. The packaging tray 10 has a base 12 and a lid 14. There are tabs 16 that extend from an outside portion 18 of the base 12 over the compartment 20 that holds optical fiber components 22. The lid 14 must be manually slid in and out of the packaging tray 10 due to the tabs 16 that are disposed over the lid 14 and the tabs 16 are not pliable. The manual slidable attachment of the lid 14 as indicated by the arrows in Fig. 2 is time consuming and the tabs 16 make it hard to automate the process of attaching the lid 14 using a robotic device.

[0041] One embodiment of a packaging tray 100 for fiber optic components 102 is illustrated in Figs. 3-13. Figs. 14-16B illustrate the packaging tray 100 attached to another packaging tray 100 in a stacked configuration.

[0042] The packaging tray 100 has a lid 104, which may be clear or at least translucent to be able to see contents of the packaging tray 100. However, it may also be opaque. The lid 104 has a top side 106 and an underside 108. There is at least one downward projection 110 extending downward and away from the underside 108 of the lid 104. See Figs. 3, 4, and 10. The at least downward projection 110 is an elongated structure that is parallel with an edge of the lid 104. There are two of downward projections 110 and they are on opposite sides of the lid 104. As noted below, each of the downward projections 110 fits, respectively, within a groove 140 in the base 120. Thus, there is at least one groove 140 provided on the base 120 and has a geometry matched to receive the at least one downward projection 110 of the lid 104.

[0043] The lid 104 also includes an opening 112 that extends through the top side 106 and the underside 108. As illustrated in Fig. 4, the opening 112 is not fully enclosed, but as an alternative implementation, the opening 112 may also be fully enclosed. TheUSCO-195-INTopening 112 is disposed between the two downward projections 110 and has walls 112a.Yet alternatively, the lid 104 may not have an opening 112.

[0044] The packaging tray 100 also includes a base 120. The base 120 has a plurality of walls 122 that form at least in part a base underside 124 and an upper side 126 of the base 120. The plurality of walls 122 may also include at least one extension 128 that extends from the walls 122 and above the upper side 126 to help in retaining the lid 104 securely with the base 120. The walls 122 are angled inwardly so that the base 120 is wider at the bottom than it is at the top. Thus, the base 120 has a configuration resembling a portion or frustum of a pyramid. See Figs. 9-11. This provides for a more stable packaging tray 100 and provides a space in which to receive another packaging tray 100 as discussed below. Two or more, e.g., 45 to 100, packaging trays, may be grouped or stacked together (by a robot).

[0045] The base 120 also includes a plurality of lid latches 130 to also secure the lid 104 on the base 120. Each of the lid latches 130 has a chamfer 130a facing away from the lid 104 and a downward facing surface 130b to engage the lid 104 during an attachment of the lid 104 to the base 120. See, e.g., Fig. 9. When the lid 104 is put on the base 120, the lid 104 engages the chamfer 130a of the lid latches 130 and flexes the lid latches 130 outward as the lid 104 is pushed toward the base 120, which allows the lid 104 to slide past the chamfers 130a and engage the base 120 with the downward facing surface 130b holding the lid 104 between the base 120 and the lid latches 130. See, e.g., Fig. 10. Alternatively, the lid latches 130 may be provided on the lid in a reversed configuration such that the base 120 receives the lid latches 130.

[0046] At the same time, the downward projections 110 are aligned with a respective groove 140 in the base 120. The downward projections 110 fit within the grooves 140 when the lid 104 is attached to the base 120. See, e.g., Figs. 10 and 11. There is an opening 142 in the wall 122 at the end of the grooves 140 to allow for the downward projections 110 to slide out of the grooves 140 when the lid is removed from the base 120.

[0047] The base 120 has a plurality of compartments 150 on the upper side 126 to respectively receive fiber optic components 102. The plurality of compartments 150 and the lid 104 are surrounded or contained on three sides by the walls 122 of the base 120. The walls 122 may continuously surround the plurality of compartments 150 or there may be some gaps in the walls 122 along a periphery thereof to accommodate other features such as the at least one extension 128. A fourth side of the base 120 is open to allow the lid 104 to be removedUSCO-195-INTupon a depression of a lid removal latch 160. The plurality of compartments 150 are arranged as adjacent rows, which is useful for removing the fiber optic components on a row-by-row basis with a partial removal of the lid 104 (by partially sliding the lid 104 out), or all together at once with a complete removal of the lid 104. In one embodiment, the plurality of compartments 150 are each sized to receive a multi-fiber ferrule. In this specific instance and, what is illustrated in the figures, are TMT ferrules provided by the applicant. Other fiber optic components 102, such as other fiber optic ferrules (lensed or physical contact) and / or other fiber optic connector components (e.g., pin clamps) may also be secured therein. As an example, the plurality of compartments 150 are configured to receive the specific fiber optic components 102. See Figs. 3, 7, 8, and 12. Additionally, the plurality of compartments 150 have a separation gap 152 between adjacent ones of the plurality of components 150. As illustrated, the separation gap 152 allows a tool (e.g., tweezers) to be inserted to carefully remove one or more of the fiber optic components for inspection or quality control, if needed. Upward extending ribs 154 form an enclosure from each of the plurality of compartments 150 except where the separation gap 152 is. The upward extending ribs 154 have a height such that when the lid 104 is secured on the base 120 of the packaging tray 100, the fiber optic components 102 will be retained within their respective compartments. See, e.g., Fig.7, 8.

[0048] The base 120 also includes the lid removal latch 160 with a free end 162 positioned in the opening 112 of the lid 104 to secure the lid 104 to the base 120. See Fig. 11. However, when there is no opening in the lid 104, the lid removal latch 160 may be provided elsewhere to secure the lid 104. For example, the lid removal latch 160 may be provided on the lid 104 itself and the base 102 may have a latch receiving portion to receive the lid removal latch 160. One of ordinary skill in the art after reading this disclosure will appreciate that in this alternative implementation (i.e., when no opening 112 exists), the lid removal latch 160 may have a different configuration than the one shown, but still have the same function. As another example, the opening 112 may be provided on the base 120 to receive the lid removal latch 160 from the lid 104. The lid removal latch 160 is a cantilever with the fixed end 164 attached to the underside of the base 120 at a position 166. A portion of the free end 162 of the lid removal latch 160 and particularly, the upward facing surface 168 of the free end 162, is above or upward of the top surface 106 of the lid 104. The lid removal latch 160 is also at an angle a (a 0) to the rest of the base 120 and the top surfaceUSCO-195-INTopening 112 and the top surface 106 of the lid 104. Depending on the configuration, simply having a portion of the lid removal latch 160 within the opening 112 and making contact with the lid 104 will secure the lid 104 onto the base 120. As a result, there is an intentional interference between walls 112a of the opening 112 in the lid 104 and the free end 162 of the lid removal latch 160. For example, a side surface 162a of the free end 162 of the lid removal latch 160 interferes with the wall 112a of the opening 112 when trying to pull the lid 104 off the base 120. See, e.g., Figs. 5 and 11. This interference prevents accidental removal of the lid 104 during shipping. The lid removal latch 160 may have other geometries as long as the upward facing surface 166 of the lid removal latch 160 is disposed at least partially above the opening 112. To subsequently remove the lid 104, the lid removal latch 160 is depressed by pushing the upward facing surface 168 to move the free end 162 out of the opening 112 (thus, removing the interference), and the lid 104 is slid out.

[0049] The lid 104 is fully engaged with the base 120 when the lid removal latch 160 is in the opening 112, the downward projections 110 are within the grooves 140, the lid 104 is captured by the lid latches 130 (the lid 104 is between the base 120 and the downward facing surfaces 130b).

[0050] The base 120 also has at least one side projection 170 extending away from the side wall 122. There are two side projections 170 shown in the figures, but there could also be more. The side projection 170 has one end 172 that extends outward and beyond the walls 122 of the base 120. The user can use the end(s) 172 to move / carry / manipulate the packaging tray 100. The user may also use it to actuate a stacking latch 174 on an opposite end thereof. The stacking latch 174 has an upward facing surface 176 and a stacking chamfer 178 that is generally facing downward (at an angle). See Figs. 11 and 16A. The stacking latch 174 is within the base underside 124 of the base 120. See Figs. 10, 11, 14 and 16A. The side projection 170 with the end 172 and the stacking latch 174 are also used to connect (stack) multiple trays on top of each other. It should be noted that the configuration of the base underside 124 of the base 120 and the upper side 126 of the base 120 are complementary in that the upper side 126 from one packaging tray 100 fits into the underside 124 of a second (another identical) packaging tray 100. Many such empty bases 120 are attached and provided to a robot, the robot unsnaps or separates individual packaging trays, loads the individual trays (e.g., with unpolished TMT ferrules), and then lid 104 is snapped for each such packaging tray 100. The packaging trays 100 are then stacked together again by the robot for shipping. Each of the packaging trays 100 also have into a window 180 in theUSCO-195-INTsidewall 122. The window 180 is above the side projection 170 and is bound in the upward direction by a beam 182 that is also a part of the side wall 122. See, e.g., Figs. 7 and 14.

[0051] To secure the two identical packaging trays 100 as shown in Figs. 14, 15, 16, 16A, and 16B, a top packaging tray onto a bottom packaging tray, the side projection 170 of each of the packaging trays 100 are aligned on the same sides. As the top packaging tray is lowered to the bottom packaging tray, each of the stacking chamfers 178 of the stacking latches 174 of the upper packaging tray engages the beams 182 of the bottom packaging tray. Continued pressure on the top packaging tray causes deflection in one or both of the beams 182 and the stacking latches 174 and the stacking latches 174 slip past the beams 182 and into the window 180. See Figs. 14 - 16B. The same process is repeated for additional packaging trays either from the top or the bottom side of the stacked arrangement of Figs. 14, 15. Prior to loading the fiber optic components, A robot may be used (e.g., with computer vision) to hold the packaging tray 100 and attach the packaging tray 100 to another packaging tray 100 loaded with components. Thus, advantageously, a fast assembly of packaging trays with fiber optic components is possible for secure shipping.

[0052] There are features on the packaging tray 100 that prevent a subsequent additional stackable packaging tray 100 from being latched incorrectly. For example, the base 120 has a rounded edge on the sides of the solid portion of the wall 122 on one side (see, e.g., Fig. 3), but has a sharp edge on other sides of the open side of the base (i.e., on either side of the opening 112 adjacent lid latches 130). This asymmetry in the shape of the base 120 acts as a polarity feature. As a result, the additional packaging tray may be attached only in one direction.

[0053] In one alternative embodiment of the packaging tray 200, the walls 222 may surround the plurality of compartments 250 on all four sides. See Fig. 17. In this embodiment, the lid 204 is a solid structure with no openings and no downward projections. That is, the lid 204 is flat. To accommodate automated attachment of removal for this embodiment, the lid latch 230 is present on all four sides of the walls 222. To attach the lid 204, the robot has to simply push the lid 204 over the chamfer 230a and snap the lid 204 to the base 220. Then, to remove the lid 204, the robot or a human user (as needed) must flare out the lid latch 230 on any one side and slide out the lid 204 over the extensions 228 thereby removing the lid 204 from the base 220. Such removal may then be carried out in any of the four possible directions since there are no projections from the lid 204.USCO-195-INT

[0054] It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

Claims

USCO-195-INTIN THE CLAIMS:We claim:

1. A packaging tray for fiber optic components, comprising:a lid having an opening; anda base having a plurality of compartments to respectively receive fiber optic components, and having a lid removal latch with a free end positioned in the opening of the lid to secure the lid to the base, andwherein upon a full engagement of the lid to the base, the lid is prevented from removal from the base by the lid removal latch,wherein the plurality of compartments and the lid are surrounded on three sides by walls of the base, a fourth side of the base being open to allow the lid to be removed upon a depression of the lid removal latch, andwherein the base has a base underside to receive an additional packaging tray.

2. The packaging tray of claim 1, wherein the plurality of compartments are each sized to receive a multi -fib er ferrule.

3. The packaging tray of claim 1, wherein the base underside is surrounded by side walls of the base, at least one side wall having at least one stacking latch to receive a beam from an additional base to stack the additional packaging tray to the packaging tray.

4. The packaging tray of claim 3, wherein the base further comprises a side projection on a side wall of the base, the side projection extending outward from the at least one stacking latch and away from the side wall, and a beam above the stacking latch to engage a base of the additional packaging tray identical to the packaging tray thereby stacking the packaging tray in a secure arrangement with the additional packaging tray.

5. The packaging tray of claim 1, wherein the fiber optic components are TMT ferrules trapped in respective ones of the plurality of compartments upon the full engagement of the lid to the base.

6. The packaging tray of claim 1, wherein there is a separation gap between two adjacent ones of the plurality of compartments.USCO-195-INT7. The packaging tray of claim 1, wherein the lid includes at least one downward projection from an underside of the lid, the at least one downward projection being an elongated structure extending parallel to an edge of the lid.

8. The packaging tray of claim 7, wherein the at least one downward projection on the lid includes two downward projections and the opening in the lid is located between the two downward projections.

9. The packaging tray of claim 1, wherein the lid removal latch is at a non-zero angle to the lid.

10. The packaging tray of claim 1, wherein the lid removal latch is joined to the base underside.

11. The packaging tray of claim 1, wherein the base also includes a plurality of lid latches each having a chamfer facing away from the lid and a downward facing surface to engage the lid during an attachment of the lid to the base.

12. The packaging tray of claim 7, wherein the at least one downward projection is received in at least one groove of the base and the free end of the lid removal latch of the base is received in the opening in the lid.

13. A packaging tray for fiber optic components, comprising:a lid; anda base having a plurality of compartments to respectively receive fiber optic components and coupled to the lid;wherein upon a full engagement of the lid to the base, the lid is prevented from removal from the base,wherein the plurality of compartments and the lid are surrounded on three sides by walls of the base, a fourth side of the base being open to allow the lid to be removed from the base, andUSCO-195-INTwherein the base has a base underside surrounded by side walls of the base to receive an additional packaging tray to form a stacked configuration of a plurality of packaging trays, at least one side wall having at least one stacking latch with an upward facing surface to receive a beam from another packaging tray.

14. The packaging tray of claim 13, wherein the lid has an opening and the base has a lid removal latch with a free end positioned in the opening of the lid to secure the lid to the base and to release the lid from the base by a depression action of the free end.

15. The packaging tray of claim 14, wherein the lid includes at least one downward projection from an underside of the lid and received in at least one groove of the base, the at least one downward projection being an elongated structure extending parallel to an edge of the lid, the free end of the lid removal latch of the base is received in the opening in the lid, andwherein the base also includes a plurality of lid latches each having a chamfer facing away from the lid and a downward facing surface to engage the lid during an attachment of the lid to the base.

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