WO2005081028A1 - Optical fiber connectors comprising high precision sleeve and submarine multi-fibre connector - Google Patents

Optical fiber connectors comprising high precision sleeve and submarine multi-fibre connector Download PDF

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Publication number
WO2005081028A1
WO2005081028A1 PCT/CA2004/000467 CA2004000467W WO2005081028A1 WO 2005081028 A1 WO2005081028 A1 WO 2005081028A1 CA 2004000467 W CA2004000467 W CA 2004000467W WO 2005081028 A1 WO2005081028 A1 WO 2005081028A1
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WO
WIPO (PCT)
Prior art keywords
fiber
terminals
terminal
connection
receptacle
Prior art date
Application number
PCT/CA2004/000467
Other languages
French (fr)
Inventor
Mikio Miyake
Original Assignee
Mikio Miyake
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mikio Miyake filed Critical Mikio Miyake
Priority to CA002596908A priority Critical patent/CA2596908A1/en
Publication of WO2005081028A1 publication Critical patent/WO2005081028A1/en

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Classifications

    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24Coupling light guides
    • G02B6/36Mechanical coupling means
    • G02B6/38Mechanical coupling means having fibre to fibre mating means
    • G02B6/3807Dismountable connectors, i.e. comprising plugs
    • G02B6/3833Details of mounting fibres in ferrules; Assembly methods; Manufacture
    • G02B6/3851Ferrules having keying or coding means
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24Coupling light guides
    • G02B6/36Mechanical coupling means
    • G02B6/38Mechanical coupling means having fibre to fibre mating means
    • G02B6/3807Dismountable connectors, i.e. comprising plugs
    • G02B6/3873Connectors using guide surfaces for aligning ferrule ends, e.g. tubes, sleeves, V-grooves, rods, pins, balls
    • G02B6/3874Connectors using guide surfaces for aligning ferrule ends, e.g. tubes, sleeves, V-grooves, rods, pins, balls using tubes, sleeves to align ferrules
    • G02B6/3877Split sleeves
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24Coupling light guides
    • G02B6/36Mechanical coupling means
    • G02B6/38Mechanical coupling means having fibre to fibre mating means
    • G02B6/3807Dismountable connectors, i.e. comprising plugs
    • G02B6/3873Connectors using guide surfaces for aligning ferrule ends, e.g. tubes, sleeves, V-grooves, rods, pins, balls
    • G02B6/3874Connectors using guide surfaces for aligning ferrule ends, e.g. tubes, sleeves, V-grooves, rods, pins, balls using tubes, sleeves to align ferrules
    • G02B6/3878Connectors using guide surfaces for aligning ferrule ends, e.g. tubes, sleeves, V-grooves, rods, pins, balls using tubes, sleeves to align ferrules comprising a plurality of ferrules, branching and break-out means
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24Coupling light guides
    • G02B6/36Mechanical coupling means
    • G02B6/38Mechanical coupling means having fibre to fibre mating means
    • G02B6/3807Dismountable connectors, i.e. comprising plugs
    • G02B6/381Dismountable connectors, i.e. comprising plugs of the ferrule type, e.g. fibre ends embedded in ferrules, connecting a pair of fibres
    • G02B6/3816Dismountable connectors, i.e. comprising plugs of the ferrule type, e.g. fibre ends embedded in ferrules, connecting a pair of fibres for use under water, high pressure connectors

Definitions

  • the present invention relates to connectors, and more particularly, to optical and electrical connectors and methods.
  • Fiber optic telecommunications networks are presently in widespread use.
  • Various methods presently exist for connecting one optical fiber to another fiber including permanent connection methods such as fusion or mechanical splicing, as well as detachable connection methods.
  • detachable connections any deviation from a precise coaxial alignment of the optical fibers results in signal loss at the point of connection, thereby disadvantageously reducing the capacity and transmission distance of the fibers.
  • existing detachable fiber connection methods typically strive for as accurate an alignment of the fibers as possible, given the limitations of conventional connection equipment.
  • One existing detachable fiber connection method involves use of an optical fiber connector unit, which consists of two ferrules, each of which has a narrow cylindrical hole axially disposed along a central axis thereof, for containing an optical fiber.
  • An inner or connection end of the first ferrule is shaped in the form of a conical male protrusion, and a connection end of the second ferrule is shaped in the form of a complementary conical female recession, for receiving the connection end of the first ferrule therein.
  • each ferrule is received in a barrel having a flange.
  • a protective sleeve may be provided between the two flanges, extending around the periphery of the ferrules and surrounding the connected connection ends of the ferrules.
  • a connection unit involving flanged barrels may be cumbersome for some applications, and it may be difficult to connect the ferrules together in some situations, such as where the ferrules are hard to reach, or where lighting conditions are non-ideal, for example.
  • conventional ferrules and sleeves typically have dimensional tolerances that still result in slight misalignments between connected ferrules, and therefore result in slight signal losses at the connection.
  • multi-terminal connectors are presently in widespread use for connecting pluralities of electrical terminals together.
  • Such multi-terminal connectors often have symmetrical or near-symmetrical shapes, such as discshapes or rectangular shapes, or nearly-rectangular trapezoidal shapes. Accordingly, the correct rotational orientation at which the connectors are to be connected together is often not immediately apparent, and may be particularly difficult to discern in situations involving dim lighting conditions, or where physical access to the connectors is limited or partly obstructed, for example.
  • an optical connector apparatus including first and second fiber terminals, and a terminal connection guide.
  • the terminal connection guide includes an alignment section extending from the first fiber terminal and having inner dimensions selected to snugly receive the second fiber terminal therein to precisely align the second fiber terminal with the first fiber terminal.
  • the inner dimensions of the alignment section have a dimensional tolerance on the order of one micron or less.
  • the inner dimensions of the alignment section may have a dimensional tolerance on the order of one-half micron or less.
  • the inner dimensions of the alignment section may have a dimensional tolerance on the order of one tenth of one micron, or less, if desired.
  • the terminal connection guide may include metal that has been electroformed to achieve the dimensional tolerance of the inner dimensions of the alignment section.
  • the inner dimensions of the alignment section may be cylindrical.
  • the terminal connection guide may have a resiliently deformable opening to resiliently receive the second fiber terminal therein.
  • the terminal connection guide serves to both resiliently receive the second fiber terminal and precisely align the two fiber terminals together, an aligned detachable connection of the two fiber terminals can be easily achieved by simply inserting the second fiber terminal into the terminal connection guide.
  • the use of the terminals and the connection guide to achieve the aligned connection may avoid the necessity of additional cumbersome equipment required in conventional connectors to achieve such an aligned connection.
  • the terminal connection guide may include a sleeve surrounding at least a portion of the first fiber terminal.
  • the sleeve may include an alignment section and a plurality of jaws extending therefrom, the jaws acting as a resiliently deformable opening of the guide to resiliently receive the second fiber terminal therein. If so, the jaws may contract radially inwardly as they extend axially away from the alignment section such that the opening has a narrower inner diameter than the alignment section.
  • the second fiber terminal may include a tip having a narrower outer diameter than the inner diameter of the opening, and a body having a greater outer diameter than the inner diameter of the opening.
  • the jaws may be resiliently radially outwardly bendable by inserting the second fiber terminal into the opening.
  • the first and second fiber terminals may have cylindrical outer surfaces
  • the alignment section may include a cylindrical inner surface having an inner circumference exceeding an outer circumference of the first and second fiber terminals by a sufficiently small amount to snugly receive the second fiber terminal in the alignment section in alignment with the first fiber terminal.
  • the first and second fiber terminals may include first and second ferrules respectively.
  • the first and second ferrules may include electroformed metal ferrules.
  • Each of the first and second fiber terminals may include at least one respective fiber channel defined therethrough, in which case the inner dimensions of the alignment section cause the at least one fiber channel of the second fiber terminal to align with the at least one fiber channel of the first fiber terminal as the second fiber terminal is inserted into the alignment section.
  • the first and second fiber terminals may include complementary connection surfaces for facilitating aligned engagement of the first and second fiber terminals with each other.
  • the first fiber terminal may have a concave connection surface and the second fiber terminal may have a convex connection surface.
  • an optical connector apparatus including first means for terminating a first fiber, second means for terminating a second fiber, and means for aligning the second means for terminating with the first means for terminating.
  • the means for aligning has a dimensional tolerance on the order of one micron or less.
  • the dimensional tolerance may be on the order of one tenth of one micron.
  • the means for aligning may be electroformed.
  • an optical connection method including inserting a second fiber terminal into an alignment section of a terminal connection guide extending from a first fiber terminal and having inner dimensions selected to snugly receive the second fiber terminal therein to precisely align the second fiber terminal with the first fiber terminal.
  • the inner dimensions have a dimensional tolerance on the order of one micron or less.
  • a connector apparatus including a receptacle including a plurality of terminals of a first type, and a plug including a plurality of terminals of a second type connectable to the terminals of the first type.
  • the receptacle and the plug include complementary connection faces configured to permit connection with each other only at a single rotational orientation relative to each other and configured to prevent connection at other relative rotational orientations.
  • the complementary connection faces permit connection only at a single relative rotational orientation, a fast and easy connection of the receptacle to the plug is facilitated.
  • the complementary connection faces that achieve this, the correct connection orientation is immediately discernible from visual inspection of the faces.
  • the plurality of terminals of the first type may include a plurality of female optical fiber terminals
  • the plurality of terminals of the second type may include a plurality of male optical fiber terminals.
  • the complementary connection faces may be planar and may be tilted relative to a common central axis extending through the receptacle and the plug when the receptacle and the plug are connected. From another perspective, the complementary connection faces may be planar, and normals to planes of the connection faces of the receptacle and the plug may be tilted relative to respective central axes of the receptacle and the plug.
  • Each of the complementary connection faces may have an irregular pentagonal shape.
  • a cross-section of the receptacle in a plane normal to the central axis of the receptacle may have an equilateral pentagonal shape
  • the connection face of the receptacle may have a non- equilateral pentagonal shape, which may result from the tilting of the connection face, for example.
  • the connector apparatus may further include a watertight housing surrounding the receptacle and the plug.
  • the connector apparatus may be suitable for underwater applications, such as sub-oceanic optical fiber connections, for example.
  • the watertight housing may include respective cable seals at opposite ends of the housing to permit entry of cables in communication with the receptacle and with the plug respectively, while preventing entry of contaminants.
  • the cable seals may include vulcanized rubber seals surrounding the cables.
  • the watertight housing may include a receptacle casing surrounding the receptacle, a plug casing surrounding the plug, and first and second cable casings each surrounding at least a portion of a respective one of the cable seals. If so, then at least a portion of the plug casing may be insertable into a portion of the receptacle casing to connect the plug to the receptacle.
  • the watertight housing may further include a connection lock casing for locking a connection between the plug casing and the receptacle casing, and connection seals for sealing the connection between the plug casing and the receptacle casing.
  • the plug may include the plurality of male optical fiber terminals at one end thereof, and the plug further may include a second receptacle at an opposite end thereof, the second receptacle including a second plurality of female optical fiber terminals.
  • Each one of the female optical fiber terminals may include a terminal connection guide extending therefrom.
  • the terminal connection guide may include an alignment section extending from the female optical fiber terminal and having inner dimensions selected to snugly receive one of the male optical fiber terminals therein to precisely align the male terminal with the female terminal.
  • the inner dimensions of the alignment section may have a dimensional tolerance on the order of one micron or less.
  • the inner dimensions of the alignment section may have a dimensional tolerance on the order of one tenth of one micron.
  • the terminal connection guide may have a resiliently deformable opening to resiliently receive one of the male optical fiber terminals therein. If so, the terminal connection guide is preferably configured to align the one of the male optical fiber terminals with the one of the female optical fiber terminals as the male optical fiber terminal is inserted into the guide.
  • a connector apparatus including first means for mounting a plurality of terminals of a first type, and second means for mounting a plurality of terminals of a second type connectable to the terminals of the first type.
  • the first and second means for mounting include means for permitting connection with each other only at a single rotational orientation relative to each other and for preventing connection at other relative rotational orientations.
  • connection method including rotating one of a receptacle including a plurality of terminals of a first type, and a plug including a plurality of terminals of a second type connectable to the terminals of the first type, relative to the other of the receptacle and the plug, until the receptacle and plug are at a single rotational orientation relative to each other at which complementary connection faces of the receptacle and of the plug are connectable to each other.
  • the method further includes connecting the complementary connection faces with each other to connect the terminals of the second type to the terminals of the first type.
  • Figure 1 is a side elevation view of an optical connector apparatus, according to a first embodiment of the invention
  • Figure 2 is a cross-section of the apparatus shown in Figure 1 ;
  • Figure 3 is a cross-section of the apparatus shown in Figures 1 and 2, shown in a connected configuration
  • Figures 4-5 show cross-sections of components of a connector apparatus according to a second embodiment of the invention.
  • Figure 6 is a front elevation view of a receptacle and a receptacle casing of the connector apparatus shown in Figure 4;
  • Figure 7 is a side elevation view of a cable casing of the connector apparatus shown in Figure 5;
  • Figure 8 is a rear elevation view of the cable casing shown in Figures 5 and 7;
  • Figure 9 is a cross-section of a plug and a plug casing of a connector apparatus according to a third embodiment of the invention.
  • an optical connector apparatus according to a first embodiment of the invention is shown generally at 100.
  • the apparatus 100 includes first and second fiber terminals 102 and 104, and a terminal connection guide shown generally at 106.
  • the terminal connection guide extends from the first fiber terminal 102, and has inner dimensions selected to snugly receive the second fiber terminal 104 therein to precisely align the second fiber terminal 104 with the first fiber terminal 102.
  • the inner dimensions of the alignment section 110 have a dimensional tolerance on the order of one micron or less. More particularly, in this embodiment the inner dimensions have a dimensional tolerance on the order of one-tenth of one micron or less. More particularly still, in the present embodiment the dimensional tolerance is approximately one tenth of one micron.
  • the terminal connection guide includes metal that has been electroformed. More particularly, in this embodiment the terminal connection guide has been electroformed in a manner similar to that described in Patent Cooperation
  • the inner dimensions of the alignment section 110 are cylindrical, with the above- noted dimensional tolerance on the order of 0.1 ⁇ m resulting from the electroforming process by which it was manufactured.
  • the terminal connection guide 106 has a resiliently deformable opening shown generally at 108, to resiliently receive the second fiber terminal 104 therein.
  • the terminal connection guide 106 is configured to align the second fiber terminal 104 with the first fiber terminal 102 as the second fiber terminal 104 is inserted into the guide 106.
  • the optical connector apparatus 100 is shown in greater detail in Figure 2.
  • the terminal connection guide
  • the 106 includes a sleeve surrounding at least a portion of the first fiber terminal 102. More particularly, in this embodiment the sleeve includes the alignment section 110 and a plurality of jaws 112 extending from the alignment section 110. In this embodiment, the jaws 112 act as the resiliently deformable opening 108 of the terminal connection guide 106, to resiliently receive the second fiber terminal 104 therein. In the present embodiment, the plurality of jaws 112 include two jaws, separated by a slot 114. Alternatively, if desired, three or more such jaws may be substituted. More generally, other types of resiliently deformable openings may be substituted if desired.
  • the jaws 112 contract radially inwardly as they extend axially away from the alignment section 110 of the terminal connection guide 106, such that the opening 108 has a narrower inner diameter than the alignment section 110.
  • the second fiber terminal 104 includes a tip 120 and a body 122. The tip 120 of the second fiber terminal 104 has a narrower outer diameter than the inner diameter of the opening 108, while the body 122 of the second fiber terminal has a greater outer diameter than the inner diameter of the opening 108.
  • the tip 120 enters the opening 108 initially without contacting the jaws 112
  • the surface of the second fiber terminal 104 passing through the opening 108 widens as the body 122 begins to enter the opening 108, which pushes the jaws 112 radially outward until a portion of the body 122 has entered the opening 108.
  • the jaws 112 of the terminal connection guide 112 are resiliently radially outwardly bendable by inserting the second fiber terminal 104 into the opening 108.
  • the alignment section 110 of the terminal connection guide 106 which surrounds a portion of the first fiber terminal 102, has inner dimensions selected to snugly receive the second fiber terminal 104 therein. More particularly, in this embodiment the first and second fiber terminals 102 and 104 have cylindrical outer surfaces, and the alignment section 110 includes a cylindrical inner surface 130 having an inner circumference exceeding an outer circumference of the first and second fiber terminals 102 and 104 by a sufficiently small amount to snugly receive the second fiber terminal 104 in the alignment section 110 in alignment with the first fiber terminal 102.
  • each of the first and second fiber terminals 102 and 104 includes at least one respective fiber channel defined therethrough. More particularly, in this embodiment the first fiber terminal 102 includes a fiber channel 142, in which an optical fiber 144 is secured. Similarly, in this embodiment the second fiber terminal 104 includes a fiber channel 146, in which an optical fiber 148 is secured. Alternatively, if desired, fiber terminals that each have more than one fiber channel defined therethrough may be substituted, such as the multi-fiber ferrules disclosed in United States Patent No. 6,419,810, which issued on July 16, 2002 to Tanaka et al., for example.
  • the first and second fiber terminals 102 and 104 include first and second ferrules respectively. More particularly, in this embodiment the first and second ferrules include electroformed metal ferrules, similar to those disclosed in the aforementioned United States Patent No. 6,419,810, the complete disclosure of which is hereby incorporated herein by reference. More particularly still, in this embodiment the ferrules include electroformed stainless steel ferrules. In this regard, such electroformed ferrules are advantageous for fiber optic applications, as their highly precise inner and outer dimensions facilitate accurate alignment of optical fiber channels defined therein. In addition, such ferrules are generally shock-proof, providing resistance against mechanical shocks of up to 20g, and are also resistant to oxidation (rusting) or other corrosion.
  • the outer diameter of the first fiber terminal 102 is identical to that of the body 122 of the second fiber terminal 104, and likewise, the diameters of the fiber channels 142 and 146 are identical, as are the axially-centered alignments of the fiber channels 142 and 146 within the respective fiber terminals 102 and 104.
  • ferrules such as ferrules made from nickel or nickel alloys, zirconia, glass or plastic for example, may be substituted, although for purposes of the present embodiment, materials with high resistance to mechanical shock and to corrosion are preferred. More generally, other types of fiber terminals may be substituted.
  • the terminal connection guide 106 is made of metal.
  • the jaws 112 of the guide 106 are resiliently radially outwardly bendable, by inserting the second fiber terminal 104 into the opening 108.
  • the alignment section 110 of the terminal connection guide 106 which surrounds a portion of the first fiber terminal 102 and which receives a portion of the second fiber terminal 104 therein, has a highly uniform cylindrical inner surface of precise constant diameter.
  • the inner dimensions of the alignment section 110 cause the fiber channel 146 of the second fiber terminal 104 to align with the fiber channel 142 of the first fiber terminal 102 as the second fiber terminal 104 is inserted into the alignment section 110.
  • materials other than metals may be substituted for the terminal connection guide 106, although it is preferred that the terminal connection guide 106 have precise, uniform inner dimensions to facilitate accurate alignment of the fiber terminals
  • the terminal connection guide 106 is soldered to the outside of the first fiber terminal 102.
  • the terminal connection guide may be integrally formed with the first fiber terminal, or may be welded thereto, or may be clamped or clipped to the first fiber terminal, using a clamp or clip (not shown). More generally, any other suitable manner of affixing the terminal connection guide 106 to the fiber terminal 102 may be substituted.
  • first and second fiber terminals 102 and 104 include complementary connection surfaces 150 and
  • connection surface 150 of the first fiber terminal 102 includes a concave connection surface
  • connection surface 152 of the second fiber terminal 104 includes a convex connection surface
  • connection surface 152 may be conical and the connection surface 150 may include a complementary conical cavity. More generally, other complementary connection surfaces may be substituted if desired.
  • an optical connection method includes inserting the second fiber terminal 104 into the alignment section 110 of the terminal connection guide 16, which extends from the first fiber terminal 102 and has inner dimensions selected to snugly receive the second fiber terminal 104 therein to precisely align the second fiber terminal 104 with the first fiber terminal 102.
  • the inner dimensions of the alignment section have a dimensional tolerance on the order of one micron or less, or more particularly, on the order of one tenth of one micron in the present embodiment.
  • inserting includes resiliently deforming the opening 108 of the terminal connection guide 106 extending from the first fiber terminal 102 to resiliently receive the second fiber terminal 104 therein.
  • the method further includes aligning the second fiber terminal 104 with the first fiber terminal 102 as the second fiber terminal 104 is inserted into the guide 106.
  • the jaws 112 of the guide 106 serve to resiliently receive the second fiber terminal 104.
  • a detachable connection in which the optical fibers 144 and 148 are precisely aligned is achieved.
  • first and second fiber terminals 102 and 104 are examples of first means for terminating a first fiber, and second means for terminating a second fiber, respectively.
  • the plurality of jaws 112 are examples of means for resiliently receiving the second means for terminating.
  • the precise dimensions of the inner surface of the alignment section 110 and the outer surfaces of the first and second fiber terminals 102 and 104, in combination with the complementary connection surfaces 150 and 152 thereof, are examples of means for aligning the second means for terminating with the first means for terminating, the means for aligning having a dimensional tolerance on the order of one micron or less, or more particularly, on the order of one tenth of one micron in the present embodiment.
  • other suitable means may be substituted.
  • the connector apparatus 400 includes a receptacle 402 and a plug 404.
  • the receptacle 402 includes a plurality of terminals of a first type shown generally at 406 in Figure 6.
  • the plug 404 includes a plurality of terminals of a second type shown generally at 410 in Figure 4, connectable to the terminals of the first type 406.
  • the receptacle 402 and the plug 404 include complementary connection faces 414 and 416 respectively.
  • the complementary connection faces 414 and 416 are configured to permit connection with each other only at a single rotational orientation relative to each other and configured to prevent connection at other relative rotational orientations.
  • an exemplary one of the plurality of terminals of the first type 406 is shown at 408 in Figure 4, and an exemplary one of the plurality of terminals of the second type 410 is shown at 412 in Figure 4.
  • the plurality of terminals of the first type 406 include sixteen such connectors.
  • only the exemplary terminals 408 and 412 are shown as falling within the plane of the cross-section of Figure 4, and fewer than the actual number of terminals of the second type 410 are shown in Figure 4. It will be appreciated that others of the plurality of terminals of the first and second types may also appear in the plane of Figure 4, but are omitted from Figure 4 for the sake of clarity.
  • the plurality of terminals of the first type 406 include female optical fiber terminals, similar to the first fiber terminal 102 shown in Figure 2.
  • the plurality of terminals of the second type 410 include male optical fiber terminals similar to the second fiber terminal 104 shown in Figure 2.
  • the terminals include metal ferrules as described above, which provide beneficial resistance to mechanical shock and to corrosion, and whose precise dimensions facilitate highly accurate alignment of the resulting fiber connections.
  • the exemplary terminal 408 includes a female optical fiber terminal 418, which in turn includes a terminal connection guide 420 including an alignment section extending from the female optical fiber terminal and having inner dimensions selected to snugly receive one of the male optical fiber terminals therein to precisely align the male terminal with the female terminal.
  • the inner dimensions of the alignment section of the terminal connection guide 420 have a dimensional tolerance on the order of one micron or less. More particularly, in this embodiment the inner dimensions have a dimensional tolerance on the order of one tenth of one micron.
  • the terminal connection guide 420 has a resiliently deformable opening 422 to resiliently receive the exemplary male optical fiber terminal 412 therein.
  • the terminal connection guide 420 is configured to align the exemplary male optical fiber terminal 412 with the exemplary female optical fiber terminal 408 as the male optical fiber terminal 412 is inserted into the guide 420.
  • other types of optical fiber terminals may be substituted.
  • the connector apparatus 400 may be used as an electrical connector rather than as an optical connector, in which case the plurality of terminals of the first and second types may include suitable electrical connection terminals.
  • the receptacle 402 and the plug 404 are composed of shock-absorbent rubber, and are surrounded by respective cylindrical sheaths 424 and 426, which in this embodiment are composed of metal.
  • the connector apparatus 400 are composed of shock-resistant and corrosion-resistant metals, such as stainless steel or other nickel alloys, for example, to provide for extended life-times and water-tight enclosures for underwater installation.
  • shock-resistant and corrosion-resistant metals such as stainless steel or other nickel alloys, for example, to provide for extended life-times and water-tight enclosures for underwater installation.
  • other embodiments of the invention may be useful for non-corrosive environments in which mechanical shock or stress is unlikely to occur, and thus, suitable materials for a given application may be substituted.
  • the complementary connection faces 414 and 416 of the receptacle 402 and of the plug 404 respectively are configured to permit connection with each other only at a single rotational orientation relative to each other and configured to prevent connection at other relative rotational orientations.
  • the complementary connection faces 414 and 416 are planar and are tilted relative to a common central axis extending through the receptacle 402 and the plug 404 when the receptacle and the plug are connected.
  • respective normals to the planes of the connection faces 414 and 416 are tilted relative to respective central axes of the receptacle 402 and the plug 404.
  • each of the complementary connection faces 414 and 416 has an irregular pentagonal shape.
  • a cross-section of the receptacle 402 in a plane normal to the central axis of the receptacle has an equilateral pentagonal shape
  • the connection face 414 of the receptacle has a non- equilateral pentagonal shape.
  • connection face 414 as shown in the front elevation view of Figure 6 visually appears to be an equilateral pentagon, it will be appreciated that this is merely a visual consequence of the fact that the receptacle 402 has an equilateral pentagonal cross-sectional shape in a plane normal to the central axis of the receptacle 402.
  • a bottom edge 430 of the connection face 414 is disposed closer to the plug 404 than an apex 432 of the connection face 414.
  • connection face 414 has upper side edges 434 and 436 and lower side edges 438 and 440, each of which is longer than the bottom edge 430. Accordingly, in this embodiment the connection face 414 itself, as viewed from a direction normal to its own tilted plane (as opposed to the Figure 6 view from a direction parallel to the central axis of the receptacle 402), is an irregular pentagonal shape.
  • a cross-section of the plug 404 in a plane normal to its central axis also has an equilateral pentagonal shape, although the connection face 416 is tilted relative to such a plane.
  • an apex 450 of the connection face 416 is disposed closer to the receptacle 402 than a bottom edge 460 of the connection face 416.
  • connection face 416 has upper side edges (not shown) equal in length to the upper side edges 434 and 436 of the connection face 414, and similarly has lower side edges (not shown) equal in length to the lower side edges 438 and 440 of the connection face 414, all of which are longer than the bottom edge 460 of the connection face 416, which is equal in length to the bottom edge
  • connection face 416 also has an irregular pentagonal shape, when viewed from a direction normal to its plane.
  • connection faces 414 and 416 of the receptacle 402 and the plug 404 are only connectable at a single rotational orientation relative to each other, namely, with the bottom edge 430 of the connection face 414 adjacent to the bottom edge 460 of the connection face 416, and the apex 432 of the connection face 414 adjacent to the apex 450 of the connection face 416.
  • the appropriate relative rotational orientation of a plug and a receptacle may not be immediately discernible
  • the appropriate relative rotational orientations of the receptacle 402 and the plug 404 are immediately apparent, and the tilted irregular connection faces 414 and 416 facilitate fast and easy connection.
  • a plurality of asymmetrically disposed slots may be provided on one of the portions 472 and 482, and a plurality of corresponding grooves (not shown) may be provided on the other one of the portions 472 and 482, to further facilitate easy alignment and connection of the receptacle 402 and the plug 404.
  • the connector apparatus 400 further includes a watertight housing surrounding the receptacle 402 and the plug 404. More particularly, in this embodiment the watertight housing includes a receptacle casing 470 surrounding the receptacle 402, and a plug casing 480 surrounding the plug 404. In the present embodiment, a portion
  • the plug casing 480 is insertable into a portion 472 of the receptacle casing 470 to connect the plug 404 to the receptacle 402. More particularly, as shown in Figure 4, the portion 482 of the plug casing 480 is insertable into a gap 474 defined between the sheath 424 surrounding the receptacle 402 and the portion 472 of the receptacle casing 470, until the portion 482 abuts against and compresses a seal 476.
  • the seal 476 includes an O-ring seal, and serves to provide a water-tight seal when compressed between the portion 482 of the plug casing 480, the portion 472 of the receptacle casing 470, and the sheath 424 surrounding the receptacle 402.
  • the watertight housing further includes a connection lock casing shown generally at 490, for locking a connection between the plug casing 480 and the receptacle casing 470, and connection seals for sealing the connection between the plug casing and the receptacle casing.
  • the connection seals include the seal 476 discussed above, and further include a seal 484 mounted on the plug casing 480.
  • the seal 484 also includes an O-ring seal.
  • the portion 482 of the plug casing 480 When the portion 482 of the plug casing 480 is inserted into the portion 472 of the receptacle casing 470 as described above, the portion 472 abuts against and compresses the seal 484, to provide a water-tight seal between the portion 472 of the receptacle casing 470, the plug casing 480, and an inner surface 492 of the connection lock casing 490.
  • connection lock casing 490 further includes a female threaded portion 496, which is connectable to a corresponding male threaded portion 498 of the receptacle casing 470.
  • the watertight housing further includes first and second cable casings 502 and 504 shown in Figure 5, which in this embodiment are identical.
  • the first cable casing 502 surrounds a cable 506, which contains a plurality of optical fibers in communication with the receptacle 402. More particularly, in this embodiment the cable 506 contains sixteen optical fibers, each of which enters the connector apparatus 400 through the cable 506 and then continues through a fiber channel of a respective one of the plurality of terminals of the first type 406 shown in Figure 6, which in this embodiment are the female optical fiber terminals as described above, such as the terminal 418 shown in
  • Figure 4 or the first fiber terminal 102 shown in Figure 2, for example.
  • Each fiber continues through its respective female optical fiber terminal until it reaches the complementary connection surface (similar to the surface 150 shown in Figure 2, for example) of the respective female optical fiber terminal.
  • the second cable casing 504 surrounds a cable
  • each of the cables 506 and 508 includes a hermetically sealed rubber cable having a rectangular cross-sectional shape, as shown in Figure 8.
  • hermetically sealed cables are typically commercially available for oceanographic applications.
  • the cables 506 and 508 are preferably sufficiently well sealed to be watertight at depths up to
  • the watertight housing of the connector apparatus 400 includes respective cable seals at opposite ends of the watertight housing to permit entry of the cables 506 and 508 in communication with the receptacle 402 and with the plug 404 respectively, while preventing entry of contaminants. More particularly, in this embodiment the watertight housing includes a first cable seal shown generally at 510, a portion of which is surrounded by the cable casing 502, and a second cable seal shown generally at 511, all of which is surrounded by the cable casing 502.
  • the water tight housing includes a third cable seal shown generally at 512, a portion of which is surrounded by the cable casing 504, and a fourth cable seal shown generally at 513, all of which is surrounded by the cable casing 504.
  • a third cable seal shown generally at 512
  • a fourth cable seal shown generally at 513, all of which is surrounded by the cable casing 504.
  • the cable seal 510 includes vulcanized rubber seals surrounding the cable 506. More particularly, in this embodiment the cable seal 510 includes a lower vulcanized rubber seal 514 and an upper vulcanized rubber seal 516, each of which is generally rectangular in shape but has a rectangular channel defined therein to accommodate half of the cable 506.
  • the cable seal 510 further includes a lower clamping member 518 and an upper clamping member 520, which in this embodiment are made of metal.
  • the cable seal 510 also includes first and second fasteners 522 and 524, which in this embodiment include bolts.
  • the lower clamping member 518 is formed integrally with a main casing body 526 of the cable casing 502.
  • the upper clamping member 520 is attached to the cable casing 502 only by virtue of the fasteners 522 and 524 which connect it to the lower clamping member 518, and thus, the upper clamping member 520 is movable up and down relative to the lower clamping member 518 by loosening or tightening the fasteners 522 and 524, respectively.
  • the available space within the rectangular channel defined within the vulcanized rubber seals 514 and 516 is less than the expected height of the cable 506, and likewise, the available space between the lower and upper clamping members 518 and 520 is less than an uncompressed height of the vulcanized rubber seals 514 and 516, so that tightening the fasteners 522 and 524 results in significant compression of the vulcanized rubber seals 514 and 516 and of the cable 506 sandwiched therebetween, thus providing a water-tight seal.
  • the cable 506 following its entry into the cable casing 502 via the cable seal 510, the cable 506 continues through the cable casing 502, and enters the cable seal 511.
  • the cable seal 511 includes a sealant region 530. More particularly, in this embodiment, within the sealant region 530, the protective rubber body of the cable 506 is terminated, leaving only the individual optical fibers contained within the cable 506 to continue through the sealant region 530.
  • the sealant region 530 When the cable has been inserted into the sealant region 530 in this manner, the sealant region 530 is injected with liquid rubber and appropriate chemicals, and is heat-treated, to effectively transform the sealant region 530 into a hermetically sealed vulcanized rubber seal, surrounding the individual optical fibers as they exit the sealant region 530.
  • Such sealant formation methods are known in the oceanographic field and need not be described further herein.
  • the cable seal 511 also includes a vulcanized rubber seal surrounding the cable 506.
  • the individual optical fibers contained within the cable 506 diverge along their respective paths to enter the respective fiber channels of the plurality of terminals of the first type 406, i.e., the female optical fiber terminals similar to the exemplary terminal 418 shown in Figure 4.
  • the cable casing 502 includes a female threaded portion 540, which is threadedly connectable to a corresponding male threaded portion 542 of the receptacle casing 470.
  • the cable casing 504 includes a female threaded portion 550, which is threadedly connectable to a corresponding male threaded portion 552 of the plug casing 480.
  • the receptacle casing 470 may include one or more additional seals, such as a seal 544 (which in this embodiment includes an O-ring), for enhancing the water-tightness of the connection between the cable casing and the receptacle casing, and likewise, the plug casing 480 may also include additional seals (not shown) if desired.
  • a seal 544 which in this embodiment includes an O-ring
  • the plug casing 480 may also include additional seals (not shown) if desired.
  • the cable 506 is first connected to the receptacle 402, and the cable 508 is connected to the plug 404. To achieve this, the cable 506 is first connected to the receptacle 402, and the cable 508 is connected to the plug 404. To achieve this, the cable
  • the sixteen individual optical fibers within the cable 506 are then hermetically sealed within the sealant region 530 as described above.
  • the sixteen individual optical fibers within the cable 506 are then secured in respective fiber channels of the plurality of terminals of the first type 406 shown in Figure 6, such as the female optical fiber terminal 418 shown in
  • the cable 508 is inserted through the cable casing 504 and is clamped within the cable seal 512, and the sixteen individual optical fibers within the cable 508 are hermetically sealed within the cable seal 513 and are secured in respective fiber channels of the plurality of terminals of the second type 410 shown in Figure 4, such as the exemplary male optical _ -24- fiber terminal 412, extending to respective connection surfaces of the male optical fiber terminals.
  • the connection lock casing 490 Prior to threading the cable casing 504 to the plug casing 480, in this embodiment the connection lock casing 490 is slid over the plug casing 480, until an inward protrusion 560 of the connection lock casing 490 abuts an outward protrusion 562 of the plug casing 480. The cable casing 504 is then inserted into the connection lock casing 490, and is securely threaded to the plug casing 480.
  • a receptacle end includes the cable 506 secured within the cable casing 502, which in turn is secured to the receptacle casing 470.
  • a plug end includes the cable 508 secured within the cable casing 504, which in turn is secured to the plug casing 480, while the connection lock casing 490 surrounds the plug casing 480 with the inward protrusion 560 of the connection lock casing abutting the outward protrusion of the plug casing 480.
  • the above pre-connection tasks may be performed at the time of manufacture of the cables 506 and 508.
  • an opposite end (not shown) of the cable 506 may include a plug end similar to that described in connection with the cable 508.
  • the cable 508 may further include a receptacle end (not shown) similar to that described in connection with the cable 506.
  • the cables 506 and 508 may be identical, and may be manufactured with both a receptacle end and a plug end, ready for immediate interconnection.
  • the receptacle 402 is then quickly and easily connected to the plug 404.
  • one of the receptacle 402 and the plug 404 shown in Figure 4 is rotated relative to the other, until the receptacle and the plug are at the single rotational orientation relative to each other at which the complementary connection faces 414 and 416 of the receptacle and of the plug are connectable to each other.
  • this single rotational orientation occurs when the apex 432 of the connection face 414 is adjacent the apex 450 of the connection face 416, and the bottom edge 430 of the connection face 414 is adjacent the bottom edge 460 of the connection face 416.
  • this relative rotational orientation is immediately visually discernible.
  • the complementary connection faces are then connected to each other to connect the terminals of the second type 410 to the terminals of the first type 406. More particularly, the portion 482 of the plug casing 480 is slid into the gap 474 defined between the portion 472 of the receptacle casing 470 and the sheath 424 surrounding the receptacle 402, until the portion 482 of the plug casing 480 abuts the seal 476, and the portion 472 of the receptacle casing 470 abuts the seal 484.
  • connection lock casing 490 and the receptacle casing 470 are then threaded together, to tightly seal the connection between the plug 404 and the receptacle 402 and thereby place each optical fiber pair in precisely-aligned abutment as shown in Figure 3, and also to compress the seals 476 and 484, thereby providing a water-tight connection.
  • the pluralities of terminals 406 and 410 of the first and second types include fiber terminals and terminal connection guides similar to those shown at 102, 104 and 106 in Figures 2 and 3, the optical fiber connections between the receptacle 402 and the plug 404 are precisely-aligned, thereby minimizing signal loss at the point of connection.
  • the receptacle 402 is an example of a first means for mounting a plurality of terminals of a first type
  • the plug 404 is an example of a second means for mounting a plurality of terminals of a second type connectable to the terminals of the first type.
  • the connection faces 414 and 416 of the receptacle and of the plug are examples of means for permitting connection between the first and second means for mounting only at a single rotational orientation relative to each other and for preventing connection at other relative rotational orientations.
  • the illustrative embodiment of the connector apparatus 400 described above involves fiber optic connections using optical fiber terminals and connection guides similar to those shown in Figure 2, alternatively, a similar connector apparatus may be suitable for electrical applications.
  • the pluralities of connectors of the first and second types 406 and 410 may alternatively include electrical connectors, if desired.
  • the plug 900 includes a plurality of male optical fiber terminals at one end thereof, but also further includes a second receptacle at an opposite end thereof, the second receptacle including a second plurality of female optical fiber terminals. More particularly in this embodiment the plug includes a plurality of terminals shown generally at 902, an exemplary one of which is shown at 904 within the plane of Figure 9.
  • the terminal 904 has first and second opposite ends 906 and 908.
  • the first end 906 is a male optical fiber terminal, similar to the second fiber terminal 104 shown in Figure 2.
  • the second end 908 of the terminal 904 includes a female optical fiber terminal similar to the first fiber terminal 102 shown in Figure 2, and thus includes a terminal connection guide 910 having a resiliently deformable opening 912 for receiving a male optical fiber terminal therein.
  • the remaining terminals 902 each have a male end (shown at the left in Figure 9) and a female end (shown at the right in Figure 9).
  • Such a configuration facilitates connection of the plug to optical fibers that have been pre-equipped with male optical fiber terminals similar to that shown at 104 in Figure 2.

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Abstract

An optical connector apparatus includes first and second fiber terminals, and a terminal connection guide including an alignment section extending from the first fiber terminal and having inner dimensions selected to snugly receive the second fiber terminal therein to precisely align the second fiber terminal with the first fiber terminal. The inner dimensions of the alignment section have a dimensional tolerance on the order of one micron or less, preferably one tenth of one micron. A connector apparatus includes a receptacle including a plurality of terminals of a first type, and a plug including a plurality of terminals of a second type connectable to the terminals of the first type. The receptacle and plug include complementary connection faces configured to permit connection with each other only at a single rotational orientation relative to each other and configured to prevent connection at other relative rotational orientations.

Description

OPTICAL FIBRE CONNECTOR COMPRISING HIGH PRECISION SLEEVE AND SUBMARINE MULTI-FIBRE CONNECTOR
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to connectors, and more particularly, to optical and electrical connectors and methods.
2. Description of Related Art
Fiber optic telecommunications networks are presently in widespread use. Various methods presently exist for connecting one optical fiber to another fiber, including permanent connection methods such as fusion or mechanical splicing, as well as detachable connection methods. In the case of detachable connections, any deviation from a precise coaxial alignment of the optical fibers results in signal loss at the point of connection, thereby disadvantageously reducing the capacity and transmission distance of the fibers. Accordingly, existing detachable fiber connection methods typically strive for as accurate an alignment of the fibers as possible, given the limitations of conventional connection equipment.
One existing detachable fiber connection method involves use of an optical fiber connector unit, which consists of two ferrules, each of which has a narrow cylindrical hole axially disposed along a central axis thereof, for containing an optical fiber. An inner or connection end of the first ferrule is shaped in the form of a conical male protrusion, and a connection end of the second ferrule is shaped in the form of a complementary conical female recession, for receiving the connection end of the first ferrule therein. When the connection end of the first ferrule is inserted into the connection end of the second ferrule, accurate alignment of the central axes of the ferrules containing the optical fibers may be achieved. The outer end of each ferrule is received in a barrel having a flange. In one embodiment, a protective sleeve may be provided between the two flanges, extending around the periphery of the ferrules and surrounding the connected connection ends of the ferrules. Although such a configuration may achieve a desired accuracy of the alignment of the optical fibers, such a connection unit involving flanged barrels may be cumbersome for some applications, and it may be difficult to connect the ferrules together in some situations, such as where the ferrules are hard to reach, or where lighting conditions are non-ideal, for example. In addition, conventional ferrules and sleeves typically have dimensional tolerances that still result in slight misalignments between connected ferrules, and therefore result in slight signal losses at the connection.
Accordingly, there is a need for an improved optical connector apparatus and method.
In addition, multi-terminal connectors are presently in widespread use for connecting pluralities of electrical terminals together. Such multi-terminal connectors often have symmetrical or near-symmetrical shapes, such as discshapes or rectangular shapes, or nearly-rectangular trapezoidal shapes. Accordingly, the correct rotational orientation at which the connectors are to be connected together is often not immediately apparent, and may be particularly difficult to discern in situations involving dim lighting conditions, or where physical access to the connectors is limited or partly obstructed, for example.
Accordingly, there is a need for an improved multi-terminal connector apparatus and method.
SUMMARY OF THE INVENTION
The present invention addresses the above needs by providing, in accordance with one aspect of the invention, an optical connector apparatus including first and second fiber terminals, and a terminal connection guide. The terminal connection guide includes an alignment section extending from the first fiber terminal and having inner dimensions selected to snugly receive the second fiber terminal therein to precisely align the second fiber terminal with the first fiber terminal. The inner dimensions of the alignment section have a dimensional tolerance on the order of one micron or less.
Advantageously, therefore, a more precise alignment of the fiber terminals can be achieved than with conventional alignment and connection methods, thereby achieving reduced signal losses at the point of connection as compared to conventional connection techniques.
The inner dimensions of the alignment section may have a dimensional tolerance on the order of one-half micron or less. For example, the inner dimensions of the alignment section may have a dimensional tolerance on the order of one tenth of one micron, or less, if desired. The terminal connection guide may include metal that has been electroformed to achieve the dimensional tolerance of the inner dimensions of the alignment section.
The inner dimensions of the alignment section may be cylindrical.
The terminal connection guide may have a resiliently deformable opening to resiliently receive the second fiber terminal therein.
Advantageously, therefore, as the terminal connection guide serves to both resiliently receive the second fiber terminal and precisely align the two fiber terminals together, an aligned detachable connection of the two fiber terminals can be easily achieved by simply inserting the second fiber terminal into the terminal connection guide. In addition, the use of the terminals and the connection guide to achieve the aligned connection may avoid the necessity of additional cumbersome equipment required in conventional connectors to achieve such an aligned connection. The terminal connection guide may include a sleeve surrounding at least a portion of the first fiber terminal.
The sleeve may include an alignment section and a plurality of jaws extending therefrom, the jaws acting as a resiliently deformable opening of the guide to resiliently receive the second fiber terminal therein. If so, the jaws may contract radially inwardly as they extend axially away from the alignment section such that the opening has a narrower inner diameter than the alignment section. In such a case, the second fiber terminal may include a tip having a narrower outer diameter than the inner diameter of the opening, and a body having a greater outer diameter than the inner diameter of the opening. The jaws may be resiliently radially outwardly bendable by inserting the second fiber terminal into the opening.
The first and second fiber terminals may have cylindrical outer surfaces, and the alignment section may include a cylindrical inner surface having an inner circumference exceeding an outer circumference of the first and second fiber terminals by a sufficiently small amount to snugly receive the second fiber terminal in the alignment section in alignment with the first fiber terminal.
The first and second fiber terminals may include first and second ferrules respectively. For example, the first and second ferrules may include electroformed metal ferrules.
Each of the first and second fiber terminals may include at least one respective fiber channel defined therethrough, in which case the inner dimensions of the alignment section cause the at least one fiber channel of the second fiber terminal to align with the at least one fiber channel of the first fiber terminal as the second fiber terminal is inserted into the alignment section.
The first and second fiber terminals may include complementary connection surfaces for facilitating aligned engagement of the first and second fiber terminals with each other. For example, the first fiber terminal may have a concave connection surface and the second fiber terminal may have a convex connection surface.
In accordance with another aspect of the invention, there is provided an optical connector apparatus including first means for terminating a first fiber, second means for terminating a second fiber, and means for aligning the second means for terminating with the first means for terminating. The means for aligning has a dimensional tolerance on the order of one micron or less. For example, the dimensional tolerance may be on the order of one tenth of one micron. The means for aligning may be electroformed.
In accordance with another aspect of the invention, there is provided an optical connection method including inserting a second fiber terminal into an alignment section of a terminal connection guide extending from a first fiber terminal and having inner dimensions selected to snugly receive the second fiber terminal therein to precisely align the second fiber terminal with the first fiber terminal. The inner dimensions have a dimensional tolerance on the order of one micron or less.
In accordance with another aspect of the invention, there is provided a connector apparatus including a receptacle including a plurality of terminals of a first type, and a plug including a plurality of terminals of a second type connectable to the terminals of the first type. The receptacle and the plug include complementary connection faces configured to permit connection with each other only at a single rotational orientation relative to each other and configured to prevent connection at other relative rotational orientations.
Advantageously, as~the complementary connection faces permit connection only at a single relative rotational orientation, a fast and easy connection of the receptacle to the plug is facilitated. In addition, as it is the complementary connection faces that achieve this, the correct connection orientation is immediately discernible from visual inspection of the faces. The plurality of terminals of the first type may include a plurality of female optical fiber terminals, and the plurality of terminals of the second type may include a plurality of male optical fiber terminals.
The complementary connection faces may be planar and may be tilted relative to a common central axis extending through the receptacle and the plug when the receptacle and the plug are connected. From another perspective, the complementary connection faces may be planar, and normals to planes of the connection faces of the receptacle and the plug may be tilted relative to respective central axes of the receptacle and the plug.
Each of the complementary connection faces may have an irregular pentagonal shape. For example, a cross-section of the receptacle in a plane normal to the central axis of the receptacle may have an equilateral pentagonal shape, and the connection face of the receptacle may have a non- equilateral pentagonal shape, which may result from the tilting of the connection face, for example.
The connector apparatus may further include a watertight housing surrounding the receptacle and the plug. Advantageously, in such embodiments, the connector apparatus may be suitable for underwater applications, such as sub-oceanic optical fiber connections, for example.
The watertight housing may include respective cable seals at opposite ends of the housing to permit entry of cables in communication with the receptacle and with the plug respectively, while preventing entry of contaminants. The cable seals may include vulcanized rubber seals surrounding the cables.
The watertight housing may include a receptacle casing surrounding the receptacle, a plug casing surrounding the plug, and first and second cable casings each surrounding at least a portion of a respective one of the cable seals. If so, then at least a portion of the plug casing may be insertable into a portion of the receptacle casing to connect the plug to the receptacle. The watertight housing may further include a connection lock casing for locking a connection between the plug casing and the receptacle casing, and connection seals for sealing the connection between the plug casing and the receptacle casing.
The plug may include the plurality of male optical fiber terminals at one end thereof, and the plug further may include a second receptacle at an opposite end thereof, the second receptacle including a second plurality of female optical fiber terminals.
Each one of the female optical fiber terminals may include a terminal connection guide extending therefrom. The terminal connection guide may include an alignment section extending from the female optical fiber terminal and having inner dimensions selected to snugly receive one of the male optical fiber terminals therein to precisely align the male terminal with the female terminal. The inner dimensions of the alignment section may have a dimensional tolerance on the order of one micron or less. For example, the inner dimensions of the alignment section may have a dimensional tolerance on the order of one tenth of one micron.
The terminal connection guide may have a resiliently deformable opening to resiliently receive one of the male optical fiber terminals therein. If so, the terminal connection guide is preferably configured to align the one of the male optical fiber terminals with the one of the female optical fiber terminals as the male optical fiber terminal is inserted into the guide.
In accordance with another aspect of the invention, there is provided a connector apparatus including first means for mounting a plurality of terminals of a first type, and second means for mounting a plurality of terminals of a second type connectable to the terminals of the first type. The first and second means for mounting include means for permitting connection with each other only at a single rotational orientation relative to each other and for preventing connection at other relative rotational orientations. ln accordance with another aspect of the invention, there is provided a connection method including rotating one of a receptacle including a plurality of terminals of a first type, and a plug including a plurality of terminals of a second type connectable to the terminals of the first type, relative to the other of the receptacle and the plug, until the receptacle and plug are at a single rotational orientation relative to each other at which complementary connection faces of the receptacle and of the plug are connectable to each other. The method further includes connecting the complementary connection faces with each other to connect the terminals of the second type to the terminals of the first type.
Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
In drawings which illustrate embodiments of the invention,
Figure 1 is a side elevation view of an optical connector apparatus, according to a first embodiment of the invention;
Figure 2 is a cross-section of the apparatus shown in Figure 1 ;
Figure 3 is a cross-section of the apparatus shown in Figures 1 and 2, shown in a connected configuration;
Figures 4-5 show cross-sections of components of a connector apparatus according to a second embodiment of the invention;
Figure 6 is a front elevation view of a receptacle and a receptacle casing of the connector apparatus shown in Figure 4; Figure 7 is a side elevation view of a cable casing of the connector apparatus shown in Figure 5;
Figure 8 is a rear elevation view of the cable casing shown in Figures 5 and 7; and
Figure 9 is a cross-section of a plug and a plug casing of a connector apparatus according to a third embodiment of the invention.
DETAILED DESCRIPTION
OPTICAL CONNECTOR
Referring to Figure 1 , an optical connector apparatus according to a first embodiment of the invention is shown generally at 100. The apparatus 100 includes first and second fiber terminals 102 and 104, and a terminal connection guide shown generally at 106. The terminal connection guide extends from the first fiber terminal 102, and has inner dimensions selected to snugly receive the second fiber terminal 104 therein to precisely align the second fiber terminal 104 with the first fiber terminal 102. In this embodiment, the inner dimensions of the alignment section 110 have a dimensional tolerance on the order of one micron or less. More particularly, in this embodiment the inner dimensions have a dimensional tolerance on the order of one-tenth of one micron or less. More particularly still, in the present embodiment the dimensional tolerance is approximately one tenth of one micron. To achieve such dimensional tolerances, in this embodiment the terminal connection guide includes metal that has been electroformed. More particularly, in this embodiment the terminal connection guide has been electroformed in a manner similar to that described in Patent Cooperation
Treaty publication no. WO 03/104871 , published on December 18, 2003, naming the present inventor as a co-inventor therein. In this embodiment, the inner dimensions of the alignment section 110 are cylindrical, with the above- noted dimensional tolerance on the order of 0.1 μm resulting from the electroforming process by which it was manufactured.
In this embodiment, the terminal connection guide 106 has a resiliently deformable opening shown generally at 108, to resiliently receive the second fiber terminal 104 therein. In the present embodiment, the terminal connection guide 106 is configured to align the second fiber terminal 104 with the first fiber terminal 102 as the second fiber terminal 104 is inserted into the guide 106.
Referring to Figures 1 and 2, the optical connector apparatus 100 is shown in greater detail in Figure 2. In this embodiment, the terminal connection guide
106 includes a sleeve surrounding at least a portion of the first fiber terminal 102. More particularly, in this embodiment the sleeve includes the alignment section 110 and a plurality of jaws 112 extending from the alignment section 110. In this embodiment, the jaws 112 act as the resiliently deformable opening 108 of the terminal connection guide 106, to resiliently receive the second fiber terminal 104 therein. In the present embodiment, the plurality of jaws 112 include two jaws, separated by a slot 114. Alternatively, if desired, three or more such jaws may be substituted. More generally, other types of resiliently deformable openings may be substituted if desired.
In this embodiment, the jaws 112 contract radially inwardly as they extend axially away from the alignment section 110 of the terminal connection guide 106, such that the opening 108 has a narrower inner diameter than the alignment section 110. Also in this embodiment, the second fiber terminal 104 includes a tip 120 and a body 122. The tip 120 of the second fiber terminal 104 has a narrower outer diameter than the inner diameter of the opening 108, while the body 122 of the second fiber terminal has a greater outer diameter than the inner diameter of the opening 108. Accordingly, as the second fiber terminal 104 is inserted into the opening 108 of the terminal connection guide 106, the tip 120 enters the opening 108 initially without contacting the jaws 112, then as the second fiber terminal 104 continues to be inserted into the opening 108, the surface of the second fiber terminal 104 passing through the opening 108 widens as the body 122 begins to enter the opening 108, which pushes the jaws 112 radially outward until a portion of the body 122 has entered the opening 108. Thus, in this embodiment, the jaws 112 of the terminal connection guide 112 are resiliently radially outwardly bendable by inserting the second fiber terminal 104 into the opening 108.
Referring to Figures 1-3, in this embodiment, the alignment section 110 of the terminal connection guide 106, which surrounds a portion of the first fiber terminal 102, has inner dimensions selected to snugly receive the second fiber terminal 104 therein. More particularly, in this embodiment the first and second fiber terminals 102 and 104 have cylindrical outer surfaces, and the alignment section 110 includes a cylindrical inner surface 130 having an inner circumference exceeding an outer circumference of the first and second fiber terminals 102 and 104 by a sufficiently small amount to snugly receive the second fiber terminal 104 in the alignment section 110 in alignment with the first fiber terminal 102.
In this embodiment, each of the first and second fiber terminals 102 and 104 includes at least one respective fiber channel defined therethrough. More particularly, in this embodiment the first fiber terminal 102 includes a fiber channel 142, in which an optical fiber 144 is secured. Similarly, in this embodiment the second fiber terminal 104 includes a fiber channel 146, in which an optical fiber 148 is secured. Alternatively, if desired, fiber terminals that each have more than one fiber channel defined therethrough may be substituted, such as the multi-fiber ferrules disclosed in United States Patent No. 6,419,810, which issued on July 16, 2002 to Tanaka et al., for example.
In the present embodiment, the first and second fiber terminals 102 and 104 include first and second ferrules respectively. More particularly, in this embodiment the first and second ferrules include electroformed metal ferrules, similar to those disclosed in the aforementioned United States Patent No. 6,419,810, the complete disclosure of which is hereby incorporated herein by reference. More particularly still, in this embodiment the ferrules include electroformed stainless steel ferrules. In this regard, such electroformed ferrules are advantageous for fiber optic applications, as their highly precise inner and outer dimensions facilitate accurate alignment of optical fiber channels defined therein. In addition, such ferrules are generally shock-proof, providing resistance against mechanical shocks of up to 20g, and are also resistant to oxidation (rusting) or other corrosion. Thus, in this embodiment, the outer diameter of the first fiber terminal 102 is identical to that of the body 122 of the second fiber terminal 104, and likewise, the diameters of the fiber channels 142 and 146 are identical, as are the axially-centered alignments of the fiber channels 142 and 146 within the respective fiber terminals 102 and 104. Alternatively, other types of ferrules, such as ferrules made from nickel or nickel alloys, zirconia, glass or plastic for example, may be substituted, although for purposes of the present embodiment, materials with high resistance to mechanical shock and to corrosion are preferred. More generally, other types of fiber terminals may be substituted.
In this embodiment, the terminal connection guide 106 is made of metal. Thus, in this embodiment the jaws 112 of the guide 106 are resiliently radially outwardly bendable, by inserting the second fiber terminal 104 into the opening 108. In this regard, the relatively small angular bending of the jaws
112 resulting from insertion of the terminal 104 into the opening 108 does not exceed a critical angle beyond which non-resilient or permanent deformation of the jaws would tend to result, and therefore, when the second fiber terminal 104 is removed from the terminal connection guide 106, the jaws 112 resiliently move back radially inwards to their original positions. In this embodiment, the alignment section 110 of the terminal connection guide 106, which surrounds a portion of the first fiber terminal 102 and which receives a portion of the second fiber terminal 104 therein, has a highly uniform cylindrical inner surface of precise constant diameter. Thus, in this embodiment, the inner dimensions of the alignment section 110 cause the fiber channel 146 of the second fiber terminal 104 to align with the fiber channel 142 of the first fiber terminal 102 as the second fiber terminal 104 is inserted into the alignment section 110. Alternatively, if desired, materials other than metals may be substituted for the terminal connection guide 106, although it is preferred that the terminal connection guide 106 have precise, uniform inner dimensions to facilitate accurate alignment of the fiber terminals
102 and 104, and that it have sufficient flexibility for the jaws 112 to resiliently bend as described herein.
In this embodiment, the terminal connection guide 106 is soldered to the outside of the first fiber terminal 102. Alternatively, the terminal connection guide may be integrally formed with the first fiber terminal, or may be welded thereto, or may be clamped or clipped to the first fiber terminal, using a clamp or clip (not shown). More generally, any other suitable manner of affixing the terminal connection guide 106 to the fiber terminal 102 may be substituted.
Referring to Figures 2 and 3, in this embodiment the first and second fiber terminals 102 and 104 include complementary connection surfaces 150 and
152 for facilitating aligned engagement of the first and second fiber terminals 102 and 104 with each other. More particularly, in this embodiment the connection surface 150 of the first fiber terminal 102 includes a concave connection surface, and the connection surface 152 of the second fiber terminal 104 includes a convex connection surface. Alternatively, if desired, the connection surface 152 may be conical and the connection surface 150 may include a complementary conical cavity. More generally, other complementary connection surfaces may be substituted if desired.
Referring to Figures 1-3, an optical connection method according to one embodiment of the invention includes inserting the second fiber terminal 104 into the alignment section 110 of the terminal connection guide 16, which extends from the first fiber terminal 102 and has inner dimensions selected to snugly receive the second fiber terminal 104 therein to precisely align the second fiber terminal 104 with the first fiber terminal 102. As noted, in this embodiment the inner dimensions of the alignment section have a dimensional tolerance on the order of one micron or less, or more particularly, on the order of one tenth of one micron in the present embodiment. In this embodiment, inserting includes resiliently deforming the opening 108 of the terminal connection guide 106 extending from the first fiber terminal 102 to resiliently receive the second fiber terminal 104 therein. The method further includes aligning the second fiber terminal 104 with the first fiber terminal 102 as the second fiber terminal 104 is inserted into the guide 106. In this regard, the jaws 112 of the guide 106 serve to resiliently receive the second fiber terminal 104. The tight fit between the precise dimensions of the inner surface of the alignment section 110 and the outer surfaces of the first and second fiber terminals 102 and 104, in combination with the complementary connection surfaces 150 and 152, serve to align the first and second fiber terminals with each other as the second fiber terminal is inserted into the terminal connection guide. Thus, as shown in Figure 3, a detachable connection in which the optical fibers 144 and 148 are precisely aligned is achieved.
In the foregoing embodiment, it will be appreciated that the first and second fiber terminals 102 and 104 are examples of first means for terminating a first fiber, and second means for terminating a second fiber, respectively. Likewise, it will be appreciated that the plurality of jaws 112 are examples of means for resiliently receiving the second means for terminating. Similarly, in this embodiment the precise dimensions of the inner surface of the alignment section 110 and the outer surfaces of the first and second fiber terminals 102 and 104, in combination with the complementary connection surfaces 150 and 152 thereof, are examples of means for aligning the second means for terminating with the first means for terminating, the means for aligning having a dimensional tolerance on the order of one micron or less, or more particularly, on the order of one tenth of one micron in the present embodiment. Alternatively, other suitable means may be substituted. MULTIPLE TERMINAL CONNECTOR
Referring to Figures 4-8, a connector apparatus according to a second embodiment of the invention is shown generally at 400 in Figures 4 and 5. In this embodiment, the connector apparatus 400 includes a receptacle 402 and a plug 404. The receptacle 402 includes a plurality of terminals of a first type shown generally at 406 in Figure 6. The plug 404 includes a plurality of terminals of a second type shown generally at 410 in Figure 4, connectable to the terminals of the first type 406. In this embodiment, the receptacle 402 and the plug 404 include complementary connection faces 414 and 416 respectively. As discussed in greater detail below, the complementary connection faces 414 and 416 are configured to permit connection with each other only at a single rotational orientation relative to each other and configured to prevent connection at other relative rotational orientations.
Referring to Figures 2, 4 and 6, an exemplary one of the plurality of terminals of the first type 406 is shown at 408 in Figure 4, and an exemplary one of the plurality of terminals of the second type 410 is shown at 412 in Figure 4. In this embodiment, as shown in Figure 6, the plurality of terminals of the first type 406 include sixteen such connectors. However, for ease of illustration, only the exemplary terminals 408 and 412 are shown as falling within the plane of the cross-section of Figure 4, and fewer than the actual number of terminals of the second type 410 are shown in Figure 4. It will be appreciated that others of the plurality of terminals of the first and second types may also appear in the plane of Figure 4, but are omitted from Figure 4 for the sake of clarity.
In this embodiment, the plurality of terminals of the first type 406 include female optical fiber terminals, similar to the first fiber terminal 102 shown in Figure 2. Similarly in this embodiment, the plurality of terminals of the second type 410 include male optical fiber terminals similar to the second fiber terminal 104 shown in Figure 2. Advantageously, therefore, in this embodiment the terminals include metal ferrules as described above, which provide beneficial resistance to mechanical shock and to corrosion, and whose precise dimensions facilitate highly accurate alignment of the resulting fiber connections. Thus, in Figure 4, the exemplary terminal 408 includes a female optical fiber terminal 418, which in turn includes a terminal connection guide 420 including an alignment section extending from the female optical fiber terminal and having inner dimensions selected to snugly receive one of the male optical fiber terminals therein to precisely align the male terminal with the female terminal. In this embodiment, the inner dimensions of the alignment section of the terminal connection guide 420 have a dimensional tolerance on the order of one micron or less. More particularly, in this embodiment the inner dimensions have a dimensional tolerance on the order of one tenth of one micron.
In this embodiment, the terminal connection guide 420 has a resiliently deformable opening 422 to resiliently receive the exemplary male optical fiber terminal 412 therein. As discussed above in connection with the terminal connection guide 106 shown in Figure 2, in this embodiment the terminal connection guide 420 is configured to align the exemplary male optical fiber terminal 412 with the exemplary female optical fiber terminal 408 as the male optical fiber terminal 412 is inserted into the guide 420. Alternatively, other types of optical fiber terminals may be substituted. Or, as a further alternative, the connector apparatus 400 may be used as an electrical connector rather than as an optical connector, in which case the plurality of terminals of the first and second types may include suitable electrical connection terminals.
In this embodiment, the receptacle 402 and the plug 404 are composed of shock-absorbent rubber, and are surrounded by respective cylindrical sheaths 424 and 426, which in this embodiment are composed of metal. Alternatively, other suitable materials may be substituted. Preferably, all metal components of the connector apparatus 400 are composed of shock-resistant and corrosion-resistant metals, such as stainless steel or other nickel alloys, for example, to provide for extended life-times and water-tight enclosures for underwater installation. Alternatively, however, other embodiments of the invention may be useful for non-corrosive environments in which mechanical shock or stress is unlikely to occur, and thus, suitable materials for a given application may be substituted.
Referring to Figures 4 and 6, as mentioned above, in this embodiment the complementary connection faces 414 and 416 of the receptacle 402 and of the plug 404 respectively, are configured to permit connection with each other only at a single rotational orientation relative to each other and configured to prevent connection at other relative rotational orientations. To achieve this, in the present embodiment the complementary connection faces 414 and 416 are planar and are tilted relative to a common central axis extending through the receptacle 402 and the plug 404 when the receptacle and the plug are connected. In other words, in this embodiment, respective normals to the planes of the connection faces 414 and 416 are tilted relative to respective central axes of the receptacle 402 and the plug 404.
Still referring to Figures 4 and 6, in this embodiment, each of the complementary connection faces 414 and 416 has an irregular pentagonal shape. For example, in this embodiment a cross-section of the receptacle 402 in a plane normal to the central axis of the receptacle has an equilateral pentagonal shape, and the connection face 414 of the receptacle has a non- equilateral pentagonal shape. In this regard, although the connection face 414 as shown in the front elevation view of Figure 6 visually appears to be an equilateral pentagon, it will be appreciated that this is merely a visual consequence of the fact that the receptacle 402 has an equilateral pentagonal cross-sectional shape in a plane normal to the central axis of the receptacle 402. However, due to the tilt of the connection face 414 relative to the central axis of the receptacle 402, a bottom edge 430 of the connection face 414 is disposed closer to the plug 404 than an apex 432 of the connection face 414. Thus, the connection face 414 has upper side edges 434 and 436 and lower side edges 438 and 440, each of which is longer than the bottom edge 430. Accordingly, in this embodiment the connection face 414 itself, as viewed from a direction normal to its own tilted plane (as opposed to the Figure 6 view from a direction parallel to the central axis of the receptacle 402), is an irregular pentagonal shape.
Similarly, in this embodiment a cross-section of the plug 404 in a plane normal to its central axis also has an equilateral pentagonal shape, although the connection face 416 is tilted relative to such a plane. Thus, an apex 450 of the connection face 416 is disposed closer to the receptacle 402 than a bottom edge 460 of the connection face 416. Thus, in this embodiment the connection face 416 has upper side edges (not shown) equal in length to the upper side edges 434 and 436 of the connection face 414, and similarly has lower side edges (not shown) equal in length to the lower side edges 438 and 440 of the connection face 414, all of which are longer than the bottom edge 460 of the connection face 416, which is equal in length to the bottom edge
430 of the connection face 414. Thus, in this embodiment the connection face 416 also has an irregular pentagonal shape, when viewed from a direction normal to its plane.
Accordingly, in this embodiment the connection faces 414 and 416 of the receptacle 402 and the plug 404 are only connectable at a single rotational orientation relative to each other, namely, with the bottom edge 430 of the connection face 414 adjacent to the bottom edge 460 of the connection face 416, and the apex 432 of the connection face 414 adjacent to the apex 450 of the connection face 416. Thus, in contrast with many conventional connectors, in which the appropriate relative rotational orientation of a plug and a receptacle may not be immediately discernible, in this embodiment the appropriate relative rotational orientations of the receptacle 402 and the plug 404 are immediately apparent, and the tilted irregular connection faces 414 and 416 facilitate fast and easy connection. If desired, a plurality of asymmetrically disposed slots (not shown) may be provided on one of the portions 472 and 482, and a plurality of corresponding grooves (not shown) may be provided on the other one of the portions 472 and 482, to further facilitate easy alignment and connection of the receptacle 402 and the plug 404.
Referring to Figures 4 and 5, in this embodiment, the connector apparatus 400 further includes a watertight housing surrounding the receptacle 402 and the plug 404. More particularly, in this embodiment the watertight housing includes a receptacle casing 470 surrounding the receptacle 402, and a plug casing 480 surrounding the plug 404. In the present embodiment, a portion
482 of the plug casing 480 is insertable into a portion 472 of the receptacle casing 470 to connect the plug 404 to the receptacle 402. More particularly, as shown in Figure 4, the portion 482 of the plug casing 480 is insertable into a gap 474 defined between the sheath 424 surrounding the receptacle 402 and the portion 472 of the receptacle casing 470, until the portion 482 abuts against and compresses a seal 476. In this embodiment, the seal 476 includes an O-ring seal, and serves to provide a water-tight seal when compressed between the portion 482 of the plug casing 480, the portion 472 of the receptacle casing 470, and the sheath 424 surrounding the receptacle 402.
In this embodiment, the watertight housing further includes a connection lock casing shown generally at 490, for locking a connection between the plug casing 480 and the receptacle casing 470, and connection seals for sealing the connection between the plug casing and the receptacle casing. More particularly, in this embodiment the connection seals include the seal 476 discussed above, and further include a seal 484 mounted on the plug casing 480. In this embodiment, the seal 484 also includes an O-ring seal. When the portion 482 of the plug casing 480 is inserted into the portion 472 of the receptacle casing 470 as described above, the portion 472 abuts against and compresses the seal 484, to provide a water-tight seal between the portion 472 of the receptacle casing 470, the plug casing 480, and an inner surface 492 of the connection lock casing 490.
In this embodiment, the connection lock casing 490 further includes a female threaded portion 496, which is connectable to a corresponding male threaded portion 498 of the receptacle casing 470.
Referring to Figures 2 and 4-8, in this embodiment the watertight housing further includes first and second cable casings 502 and 504 shown in Figure 5, which in this embodiment are identical. In this embodiment, the first cable casing 502 surrounds a cable 506, which contains a plurality of optical fibers in communication with the receptacle 402. More particularly, in this embodiment the cable 506 contains sixteen optical fibers, each of which enters the connector apparatus 400 through the cable 506 and then continues through a fiber channel of a respective one of the plurality of terminals of the first type 406 shown in Figure 6, which in this embodiment are the female optical fiber terminals as described above, such as the terminal 418 shown in
Figure 4 or the first fiber terminal 102 shown in Figure 2, for example. Each fiber continues through its respective female optical fiber terminal until it reaches the complementary connection surface (similar to the surface 150 shown in Figure 2, for example) of the respective female optical fiber terminal.
Similarly, in this embodiment the second cable casing 504 surrounds a cable
508, which in this embodiment also contains sixteen optical fibers in communication with the plug 404. Each of the optical fibers enters the connector apparatus 400 through the cable 508 and continues through a fiber channel of a respective one of a plurality of terminals of the second type 410 shown in Figure 4, which in this embodiment are male optical fiber terminals as described above, such as the exemplary terminal 412 shown in Figure 4 or the second fiber terminal 104 shown in Figure 2, 'for example. Each fiber continues through its respective male optical fiber terminal until it reaches the complementary connection surface (similar to the surface 152 shown in Figure 2, for example). In this embodiment, each of the cables 506 and 508 includes a hermetically sealed rubber cable having a rectangular cross-sectional shape, as shown in Figure 8. In this regard, hermetically sealed cables are typically commercially available for oceanographic applications. In this embodiment, the cables 506 and 508 are preferably sufficiently well sealed to be watertight at depths up to
6 km underwater.
Referring to Figures 5, 7 and 8, in this embodiment, the watertight housing of the connector apparatus 400 includes respective cable seals at opposite ends of the watertight housing to permit entry of the cables 506 and 508 in communication with the receptacle 402 and with the plug 404 respectively, while preventing entry of contaminants. More particularly, in this embodiment the watertight housing includes a first cable seal shown generally at 510, a portion of which is surrounded by the cable casing 502, and a second cable seal shown generally at 511, all of which is surrounded by the cable casing 502. Also in this embodiment, the water tight housing includes a third cable seal shown generally at 512, a portion of which is surrounded by the cable casing 504, and a fourth cable seal shown generally at 513, all of which is surrounded by the cable casing 504. As the cable seal 510 is identical to the cable seal 512 and the cable seal 511 is identical to the cable seal 513, only the cable seals 510 and 511 are described in detail.
In this embodiment, the cable seal 510 includes vulcanized rubber seals surrounding the cable 506. More particularly, in this embodiment the cable seal 510 includes a lower vulcanized rubber seal 514 and an upper vulcanized rubber seal 516, each of which is generally rectangular in shape but has a rectangular channel defined therein to accommodate half of the cable 506. The cable seal 510 further includes a lower clamping member 518 and an upper clamping member 520, which in this embodiment are made of metal. The cable seal 510 also includes first and second fasteners 522 and 524, which in this embodiment include bolts. In this embodiment, the lower clamping member 518 is formed integrally with a main casing body 526 of the cable casing 502. In contrast, in this embodiment the upper clamping member 520 is attached to the cable casing 502 only by virtue of the fasteners 522 and 524 which connect it to the lower clamping member 518, and thus, the upper clamping member 520 is movable up and down relative to the lower clamping member 518 by loosening or tightening the fasteners 522 and 524, respectively. In this embodiment, the available space within the rectangular channel defined within the vulcanized rubber seals 514 and 516 is less than the expected height of the cable 506, and likewise, the available space between the lower and upper clamping members 518 and 520 is less than an uncompressed height of the vulcanized rubber seals 514 and 516, so that tightening the fasteners 522 and 524 results in significant compression of the vulcanized rubber seals 514 and 516 and of the cable 506 sandwiched therebetween, thus providing a water-tight seal.
Referring to Figures 4 and 5, in this embodiment, following its entry into the cable casing 502 via the cable seal 510, the cable 506 continues through the cable casing 502, and enters the cable seal 511. In this embodiment, the cable seal 511 includes a sealant region 530. More particularly, in this embodiment, within the sealant region 530, the protective rubber body of the cable 506 is terminated, leaving only the individual optical fibers contained within the cable 506 to continue through the sealant region 530. When the cable has been inserted into the sealant region 530 in this manner, the sealant region 530 is injected with liquid rubber and appropriate chemicals, and is heat-treated, to effectively transform the sealant region 530 into a hermetically sealed vulcanized rubber seal, surrounding the individual optical fibers as they exit the sealant region 530. Such sealant formation methods are known in the oceanographic field and need not be described further herein. Thus, in the present embodiment the cable seal 511 also includes a vulcanized rubber seal surrounding the cable 506.
Following passage through the cable seal 511 , the individual optical fibers contained within the cable 506 diverge along their respective paths to enter the respective fiber channels of the plurality of terminals of the first type 406, i.e., the female optical fiber terminals similar to the exemplary terminal 418 shown in Figure 4.
Referring to Figures 4 and 5, in this embodiment the cable casing 502 includes a female threaded portion 540, which is threadedly connectable to a corresponding male threaded portion 542 of the receptacle casing 470. Similarly, in this embodiment the cable casing 504 includes a female threaded portion 550, which is threadedly connectable to a corresponding male threaded portion 552 of the plug casing 480. If desired, the receptacle casing 470 may include one or more additional seals, such as a seal 544 (which in this embodiment includes an O-ring), for enhancing the water-tightness of the connection between the cable casing and the receptacle casing, and likewise, the plug casing 480 may also include additional seals (not shown) if desired.
In operation, referring to Figures 2 and 4-6, prior to connecting the receptacle 402 to the plug 404, the cable 506 is first connected to the receptacle 402, and the cable 508 is connected to the plug 404. To achieve this, the cable
506 is inserted through the cable casing 502 and is clamped within the cable seal 510, and the sixteen individual optical fibers within the cable 506 are then hermetically sealed within the sealant region 530 as described above. The sixteen individual optical fibers within the cable 506 are then secured in respective fiber channels of the plurality of terminals of the first type 406 shown in Figure 6, such as the female optical fiber terminal 418 shown in
Figure 4, for example, extending to respective connection surfaces of the female optical fiber terminals. The cable casing 502 is securely threaded to the receptacle casing 470.
Likewise, at the plug end, the cable 508 is inserted through the cable casing 504 and is clamped within the cable seal 512, and the sixteen individual optical fibers within the cable 508 are hermetically sealed within the cable seal 513 and are secured in respective fiber channels of the plurality of terminals of the second type 410 shown in Figure 4, such as the exemplary male optical _ -24- fiber terminal 412, extending to respective connection surfaces of the male optical fiber terminals. Prior to threading the cable casing 504 to the plug casing 480, in this embodiment the connection lock casing 490 is slid over the plug casing 480, until an inward protrusion 560 of the connection lock casing 490 abuts an outward protrusion 562 of the plug casing 480. The cable casing 504 is then inserted into the connection lock casing 490, and is securely threaded to the plug casing 480.
Thus, prior to connection, a receptacle end includes the cable 506 secured within the cable casing 502, which in turn is secured to the receptacle casing 470. Likewise, a plug end includes the cable 508 secured within the cable casing 504, which in turn is secured to the plug casing 480, while the connection lock casing 490 surrounds the plug casing 480 with the inward protrusion 560 of the connection lock casing abutting the outward protrusion of the plug casing 480.
Preferably, the above pre-connection tasks may be performed at the time of manufacture of the cables 506 and 508. If so, in addition to the receptacle end of the cable 506 as described herein, an opposite end (not shown) of the cable 506 may include a plug end similar to that described in connection with the cable 508. Conversely, in addition to its plug end described herein, the cable 508 may further include a receptacle end (not shown) similar to that described in connection with the cable 506. In other words, the cables 506 and 508 may be identical, and may be manufactured with both a receptacle end and a plug end, ready for immediate interconnection.
Accordingly, once the foregoing pre-connection tasks have been performed, the receptacle 402 is then quickly and easily connected to the plug 404.
To achieve this, referring to Figures 3-6, one of the receptacle 402 and the plug 404 shown in Figure 4 is rotated relative to the other, until the receptacle and the plug are at the single rotational orientation relative to each other at which the complementary connection faces 414 and 416 of the receptacle and of the plug are connectable to each other. It will be recalled that in the present embodiment, this single rotational orientation occurs when the apex 432 of the connection face 414 is adjacent the apex 450 of the connection face 416, and the bottom edge 430 of the connection face 414 is adjacent the bottom edge 460 of the connection face 416. Advantageously, due to the complementary connection faces, this relative rotational orientation is immediately visually discernible. The complementary connection faces are then connected to each other to connect the terminals of the second type 410 to the terminals of the first type 406. More particularly, the portion 482 of the plug casing 480 is slid into the gap 474 defined between the portion 472 of the receptacle casing 470 and the sheath 424 surrounding the receptacle 402, until the portion 482 of the plug casing 480 abuts the seal 476, and the portion 472 of the receptacle casing 470 abuts the seal 484. At this point, all of the plurality of connectors of the second type 410, or more particularly the male optical fiber terminals of the present embodiment, have been inserted into their corresponding plurality of connectors of the first type 406, or more particularly the female optical fiber terminals and terminal connection guides of the present embodiment. The threaded portions 496 and 498 of the connection lock casing 490 and the receptacle casing 470 are then threaded together, to tightly seal the connection between the plug 404 and the receptacle 402 and thereby place each optical fiber pair in precisely-aligned abutment as shown in Figure 3, and also to compress the seals 476 and 484, thereby providing a water-tight connection.
Referring to Figures 2-4, advantageously in this embodiment, because the pluralities of terminals 406 and 410 of the first and second types include fiber terminals and terminal connection guides similar to those shown at 102, 104 and 106 in Figures 2 and 3, the optical fiber connections between the receptacle 402 and the plug 404 are precisely-aligned, thereby minimizing signal loss at the point of connection. ln the description of the foregoing embodiment, it will be appreciated that the receptacle 402 is an example of a first means for mounting a plurality of terminals of a first type, and the plug 404 is an example of a second means for mounting a plurality of terminals of a second type connectable to the terminals of the first type. The connection faces 414 and 416 of the receptacle and of the plug are examples of means for permitting connection between the first and second means for mounting only at a single rotational orientation relative to each other and for preventing connection at other relative rotational orientations.
ALTERNATIVES
Referring to Figures 2 and 4, although the illustrative embodiment of the connector apparatus 400 described above involves fiber optic connections using optical fiber terminals and connection guides similar to those shown in Figure 2, alternatively, a similar connector apparatus may be suitable for electrical applications. Thus, the pluralities of connectors of the first and second types 406 and 410 may alternatively include electrical connectors, if desired.
Referring to Figures 2, 4 and 9, a modified plug of a connector apparatus according to a third embodiment of the invention is shown generally at 900. In this embodiment, the plug 900 includes a plurality of male optical fiber terminals at one end thereof, but also further includes a second receptacle at an opposite end thereof, the second receptacle including a second plurality of female optical fiber terminals. More particularly in this embodiment the plug includes a plurality of terminals shown generally at 902, an exemplary one of which is shown at 904 within the plane of Figure 9. The terminal 904 has first and second opposite ends 906 and 908. In this embodiment, the first end 906 is a male optical fiber terminal, similar to the second fiber terminal 104 shown in Figure 2. However, in this embodiment the second end 908 of the terminal 904 includes a female optical fiber terminal similar to the first fiber terminal 102 shown in Figure 2, and thus includes a terminal connection guide 910 having a resiliently deformable opening 912 for receiving a male optical fiber terminal therein. Likewise, the remaining terminals 902 each have a male end (shown at the left in Figure 9) and a female end (shown at the right in Figure 9). Such a configuration facilitates connection of the plug to optical fibers that have been pre-equipped with male optical fiber terminals similar to that shown at 104 in Figure 2.
While specific embodiments of the invention have been described and illustrated, such embodiments should be considered illustrative of the invention only and not as limiting the invention as construed in accordance with the accompanying claims.

Claims

What is claimed is:
1. An optical connector apparatus comprising: first and second fiber terminals; and a terminal connection guide comprising an alignment section extending from the first fiber terminal and having inner dimensions selected to snugly receive the second fiber terminal therein to precisely align the second fiber terminal with the first fiber terminal, wherein the inner dimensions of the alignment section have a dimensional tolerance on the order of one micron or less.
2. The apparatus of claim 1 wherein the inner dimensions of the alignment section have a dimensional tolerance on the order of one- half micron or less.
3. The apparatus of claim 1 wherein the inner dimensions of the alignment section have a dimensional tolerance on the order of one tenth of one micron or less.
4. The apparatus of claim 1 wherein the inner dimensions of the alignment section have a dimensional tolerance on the order of one tenth of one micron.
5. The apparatus of claim 1 wherein the terminal connection guide comprises metal that has been electroformed to achieve the dimensional tolerance of the inner dimensions of the alignment section.
6. The apparatus of claim 1 wherein the inner dimensions of the alignment section are cylindrical.
7. The apparatus of claim 1 wherein said terminal connection guide comprises a resiliently deformable opening to resiliently receive the second fiber terminal therein.
8. The apparatus of claim 1 wherein said terminal connection guide comprises a sleeve surrounding at least a portion of said first fiber terminal.
9. The apparatus of claim 8 wherein said sleeve comprises said alignment section and a plurality of jaws extending therefrom, said jaws acting as a resiliently deformable opening of said guide to resiliently receive the second fiber terminal therein.
10. The apparatus of claim 9 wherein: said jaws contract radially inwardly as they extend axially away from said alignment section such that said opening has a narrower inner diameter than said alignment section; said second fiber terminal comprises: a tip having a narrower outer diameter than said inner diameter of said opening, and a body having a greater outer diameter than said inner diameter of said opening; and said jaws are resiliently radially outwardly bendable by inserting said second fiber terminal into said opening.
11. The apparatus of claim 1 wherein said first and second fiber terminals have cylindrical outer surfaces, and wherein said alignment section comprises a cylindrical inner surface having an inner circumference exceeding an outer circumference of said first and second fiber terminals by a sufficiently small amount to snugly receive the second fiber terminal in said alignment section in alignment with the first fiber terminal.
12. The apparatus of claim 1 wherein said first and second fiber terminals comprises first and second ferrules respectively.
13. The apparatus of claim 12 wherein said first and second ferrules comprise electroformed metal ferrules.
14. The apparatus of claim 1 wherein each of said first and second fiber terminals comprises at least one respective fiber channel defined therethrough, and wherein said inner dimensions of said alignment section cause the at least one fiber channel of the second fiber terminal to align with the at least one fiber channel of the first fiber terminal as said second fiber terminal is inserted into said alignment section.
15. The apparatus of claim 1 wherein said first and second fiber terminals comprise complementary connection surfaces for facilitating aligned engagement of said first and second fiber terminals with each other.
16. The apparatus of claim 15 wherein said first fiber terminal has a concave connection surface and wherein said second fiber terminal has a convex connection surface.
17. An optical connector apparatus comprising: first means for terminating a first fiber; second means for terminating a second fiber; and means for aligning said second means for terminating with said first means for terminating, said means for aligning having a dimensional tolerance on the order of one micron or less.
18. The apparatus of claim 17 wherein said dimensional tolerance is on the order of one tenth of one micron.
19. The apparatus of claim 17 wherein said means for aligning is electroformed.
20. An optical connection method comprising inserting a second fiber terminal into an alignment section of a terminal connection guide extending from a first fiber terminal and having inner dimensions selected to snugly receive the second fiber terminal therein to precisely align the second fiber terminal with the first fiber terminal, the inner dimensions having a dimensional tolerance on the order of one micron or less.
21. A connector apparatus comprising: a receptacle comprising a plurality of terminals of a first type; and a plug comprising a plurality of terminals of a second type connectable to said terminals of said first type; wherein said receptacle and said plug comprise complementary connection faces configured to permit connection with each other only at a single rotational orientation relative to each other and configured to prevent connection at other relative rotational orientations.
22. The apparatus of claim 21 wherein said plurality of terminals of said first type comprises a plurality of female optical fiber terminals, and wherein said plurality of terminals of said second type comprises a plurality of male optical fiber terminals.
23. The apparatus of claim 22 wherein said complementary connection faces are planar and are tilted relative to a common central axis extending through said receptacle and said plug when said receptacle and said plug are connected.
24. The apparatus of claim 21 wherein said complementary connection faces are planar, and wherein normals to planes of said connection faces of said receptacle and said plug are tilted relative to respective central axes of said receptacle and said plug.
25. The apparatus of claim 21 wherein each of said complementary connection faces has an irregular pentagonal shape.
26. The apparatus of claim 24 wherein a cross-section of said receptacle in a plane normal to said central axis of said receptacle has an equilateral pentagonal shape, and wherein said connection face of said receptacle has a non-equilateral pentagonal shape.
27. The apparatus of claim 21 further comprising a watertight housing surrounding said receptacle and said plug.
28. The apparatus of claim 27 wherein said watertight housing comprises respective cable seals at opposite ends of the housing to permit entry of cables in communication with said receptacle and with said plug respectively, while preventing entry of contaminants.
29. The apparatus of claim 28 wherein said cable seals comprise vulcanized rubber seals surrounding said cables.
30. The apparatus of claim 29 wherein said watertight housing comprises a receptacle casing surrounding said receptacle, a plug casing surrounding said plug, and first and second cable casings each surrounding at least a portion of a respective one of said cable seals.
31. The apparatus of claim 30 wherein at least a portion of said plug casing is insertable into a portion of said receptacle casing to connect said plug to said receptacle.
32. The apparatus of claim 30 wherein said watertight housing further comprises a connection lock casing for locking a connection between said plug casing and said receptacle casing, and connection seals for sealing the connection between said plug casing and said receptacle casing.
33. The apparatus of claim 22 wherein said plug comprises said plurality of male optical fiber terminals at one end thereof, and wherein said plug further comprises a second receptacle at an opposite end thereof, said second receptacle comprising a second plurality of female optical fiber terminals.
34. The apparatus of claim 22 wherein each one of said female optical fiber terminals comprises a terminal connection guide extending therefrom, said terminal connection guide comprising an alignment section extending from the female optical fiber terminal and having inner dimensions selected to snugly receive one of the male optical fiber terminals therein to precisely align the male terminal with the female terminal, wherein the inner dimensions of the alignment section have a dimensional tolerance on the order of one micron or less.
35. The apparatus of claim 34 wherein the inner dimensions of the alignment section have a dimensional tolerance on the order of one tenth of one micron.
36. The apparatus of claim 34 wherein the terminal connection guide has a resiliently deformable opening to resiliently receive one of the male optical fiber terminals therein, wherein said terminal connection guide is configured to align said one of said male optical fiber terminals with said one of said female optical fiber terminals as said male optical fiber terminal is inserted into said guide.
37. A connector apparatus comprising: first means for mounting a plurality of terminals of a first type; second means for mounting a plurality of terminals of a second type connectable to said terminals of said first type; wherein said first and second means for mounting comprise means for permitting connection with each other only at a single rotational orientation relative to each other and for preventing connection at other relative rotational orientations.
38. A connection method comprising: rotating one of a receptacle comprising a plurality of terminals of a first type, and a plug comprising a plurality of terminals of a second type connectable to said terminals of said first type, relative to the other of the receptacle and the plug, until the receptacle and plug are at a single rotational orientation relative to each other at which complementary connection faces of the receptacle and of the plug are connectable to each other; and connecting said complementary connection faces with each other to connect said terminals of said second type to said terminals of said first type.
PCT/CA2004/000467 2004-02-25 2004-03-31 Optical fiber connectors comprising high precision sleeve and submarine multi-fibre connector WO2005081028A1 (en)

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