WO2022266433A1

WO2022266433A1 - Fiber optic processing systems and methods

Info

Publication number: WO2022266433A1
Application number: PCT/US2022/033976
Authority: WO
Inventors: Chinmay M. BENDALE; Paige E. CANZONIERI; Jaime Gonzalez Batista; Laurens Izaäk VAN WUIJCKHUIJSE; Scott L. CARLSON
Original assignee: Commscope Technologies Llc
Priority date: 2021-06-18
Filing date: 2022-06-17
Publication date: 2022-12-22

Abstract

Processing operations allow multi-fiber ferrules and ferrule boots to be efficiently installed on sets of optical fibers. The processing operations can include the use of clip systems, ferrule installation systems and ferrule boot installation systems.

Description

FIBER OPTIC PROCESSING SYSTEMS AND METHODS

CROSS-REFERENCE TO RELATED APPLICATIONS This application is being filed on June 17, 2022 as a PCT International Patent Application and claims the benefit of U.S. Patent Application Serial No. 63/212,237, filed on June 18, 2021, the disclosure of which is incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates generally to methods and systems for processing components of fiber optic connectors. More particularly, the present disclosure relates to methods for processing optical fibers used in fiber optic connectors.

BACKGROUND

Fiber optic communication systems are becoming prevalent in part because service providers want to deliver high bandwidth communication capabilities (e.g., data and voice) to customers. Fiber optic communication systems employ a network of fiber optic cables to transmit large volumes of data and voice signals over relatively long distances. Fiber optic connectors are an important part of most fiber optic communication systems. Fiber optic connectors allow optical fibers to be quickly optically connected without requiring a splice. Fiber optic connectors can include single fiber connectors and multi -fiber connectors.

A typical fiber optic connector includes a ferrule assembly supported at a distal end of a connector housing. A spring is used to bias the ferrule assembly in a distal direction relative to the connector housing. The ferrule functions to support an end portion of at least one optical fiber (in the case of a multi-fiber ferrule, the ends of multiple fibers are supported). The ferrule has a distal end face at which a polished end of the optical fiber is located. When two fiber optic connectors are interconnected, the distal end faces of the ferrules abut one another, and the ferrules are forced proximally relative to their respective connector housings against the bias of their respective springs. With the fiber optic connectors connected, their respective optical fibers are coaxially aligned such that the end faces of the optical fibers directly oppose one another. In this way, an optical signal can be transmitted from optical fiber to optical fiber through the aligned end faces of the optical fibers. U.S. Patent Nos. 5,883,995 and 6,142,676, which are hereby incorporated by reference in their entireties, disclose a ferrule-less fiber optic connector having an optical fiber having a ferrule-less end portion that is accessible at a front end of a connector body of the fiber optic connector. U.S. Patent No. 6,957,920, which is hereby incorporated by reference in its entirety, discloses a multi-fiber ferrule having protruding optical fibers.

The manufacturing of optical connectors typically includes many steps and is cost and time intensive. WO 2017/087849 discloses methods and systems for simplifying the operations involved in processing fiber optic connectors. During the manufacture of fiber optic connectors, clips are used to hold optical fibers during processes such as stripping, cleaving and ferrule insertion. Example clips for holding optical fibers are disclosed by U.S. Patent Nos. 5,524,167 and 8,485,735.

Alternative methods and systems for simplifying the operations involved in processing fiber optic connectors are desirable.

SUMMARY

Aspects of the present disclosure relate to devices, processes, stations, fiber holding clips and methods for enhancing the efficiency for manufacturing optical fiber and ferrule assemblies.

One aspect of the present disclosure relates to a system for processing fiber optic connectors. The system includes a fiber clip for holding a multi-fiber ferrule defining a plurality of fiber openings arranged in a row with the fiber openings being separated by a center-to-center spacing. The system also includes a fiber clip for holding a plurality of optical fibers at the same center-to-center spacing as the fiber openings of the multi-fiber ferrule with end portions of the optical fibers projecting outwardly from the fiber clip. The system further includes a ferrule installation device including a ferrule clip mounting location for mounting the ferrule clip and a fiber clip mounting location for mounting the fiber clip. The ferrule clip and the fiber clip mounting locations are positioned such that when the ferrule clip and the fiber clip are mounted therein the optical fibers held by the fiber clip align with the fiber openings of the multi-fiber ferrule. The ferrule installation device includes a linear guide for guiding linear relative movement between the ferrule clip mounting location and the fiber clip mounting location from a pre-inserted state in which the end portions of the optical fibers are offset from the fiber openings and an inserted state in which the end portions of the optical fibers are inserted into the fiber openings of the multi -fiber ferrule. The ferrule clip and the fiber clip have a mating coupling interface that aligns the ferrule clip and the fiber clip relative to one another and couples the ferrule clip and the fiber clip together when the ferrule installation device is moved from the pre-inserted state to the inserted state. The mating coupling interface couples the ferrule clip and the fiber clip together such that the ferrule clip and the fiber clip can be removed from the ferrule installation device as a unit after the optical fibers have been inserted into the multi -fiber ferrule.

Another aspect of the present disclosure relates to a system for processing fiber optic connectors. The system includes a fiber clip for holding optical fibers with end portions of the optical fibers projecting outwardly from the fiber clip. The system also includes a ferrule boot installation device. The ferrule boot installation device includes a fiber clip mounting location for mounting the fiber clip and a ferrule boot mounting location for mounting a ferrule boot. The ferrule boot installation device includes a linear guide for guiding linear relative movement between the ferrule boot mounting location and the fiber clip mounting location from a pre-inserted state in which the end portions of the optical fibers are offset from the ferrule boot and an inserted state in which the end portions of the optical fibers are inserted through the ferrule boot. The ferrule boot installation device can also be positioned in an intermediate state between the pre-inserted state and the inserted state. When the ferrule boot installation device is in the intermediate state, the end portions of the optical fibers are inserted into the ferrule boot an insertion distance less than when the ferrule boot installation device is in the inserted state. The ferrule boot installation device further includes a fiber clamp positioned between the fiber clip mounting location and the ferrule boot mounting location for clamping the end portions of the optical fibers when the fiber clip is mounted at the fiber clip mounting location. The fiber clamp is movable between an open clamp position and a closed clamp position. The fiber clamp includes a cam surface for causing the fiber clamp to be forced from the closed clamp position toward the open clamp position when the ferrule boot installation device reaches the intermediate state as the ferrule boot installation device is in the process of being moved from the pre-inserted state to the inserted state.

Another aspect of the present disclosure relates to a ferrule installation device. The ferrule installation device includes a ferrule clip mounting location for mounting a ferrule clip and a fiber clip mounting location for mounting a fiber clip. The ferrule clip and fiber clip mounting locations are positioned such that when the ferrule clip and the fiber clip are mounted therein, optical fibers held by the fiber clip align with fiber openings of a multi -fiber ferrule held by the ferrule clip. The ferrule installation device also includes a linear guide for guiding linear movement between the ferrule clip mounting location and the fiber clip mounting location from a pre -inserted state in which end portions of the optical fibers are offset from the fiber openings and an inserted state in which the end portions of the optical fibers are inserted into the fiber openings of the multi -fiber ferrule. Linear movement between the fiber clip mounting location and the ferrule clip mounting location is along a first dimension parallel to the fiber openings and the optical fibers. The fiber clip mounting location is movable along a second dimension perpendicular with respect to the first dimension to allow the fiber end portions to be moved along the second dimension when the ferrule installation device is at an intermediate state between the pre-inserted state and the inserted state.

Another aspect of the present disclosure relates to a clip system. The clip system includes a ferrule clip for holding a multi-fiber ferrule defining a plurality of fiber openings arranged in a row with the fiber opening separated by a center-to-center spacing. The clip system also includes a fiber clip for holding a plurality of optical fibers at the same center-to-center spacing as the fiber openings with end portions of the optical fibers projecting outwardly from the fiber clip. The ferrule clip and the fiber clip have a mating coupling interface that aligns the ferrule clip and the fiber clip relative to one another and couples the ferrule clip and the fiber clip together. The mating coupling interface couples the ferrule clip and the fiber clip together such that the ferrule clip and the fiber clip can be moved as a unit after the optical fibers have been inserted into the multi-fiber ferrule. The coupling can be configured to maintain a fiber protrusion length beyond an end face of the ferrule.

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

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a flow chart outlining a process in accordance with the principles of the present disclosure; Figure 2 depicts a clip system in accordance with the principles of the present disclosure;

Figure 3 depicts a fiber clip of the clip system of figure 2 shown in a closed position;

Figure 4 depicts the fiber clip of figure 3 in an open position;

Figure 5 depicts a ferrule clip of the clip system of figure 2 in a closed position;

Figure 6 depicts the ferrule clip of figure 5 in an open position;

Figure 7 is a first longitudinal cross-sectional view through the clip system of figure 2;

Figure 8 is a second longitudinal cross-sectional view through the clip system of figure 2;

Figure 9 is a perspective view of a ferrule installation device in accordance with the principles of the present disclosure;

Figure 10 is atop view of the ferrule installation device of figure 9 shown in a pre-inserted state;

Figure 11 is a cross-sectional view taken along section line 11-11 of figure

10;

Figure 12 is a side view of the ferrule installation device of figure 10; Figure 13 is atop view of the ferrule installation device of figure 9 shown in an inserted state;

Figure 14 is a cross-sectional view taken along section line 14-14 of figure

13;

Figure 15 depicts the ferrule installation device of figure 9 in an intermediate state with the structure holding the fiber clip in an elevated state;

Figure 16 depicts the ferrule installation device of figure 9 in the intermediate state with the structure holding the fiber clip in a lowered state;

Figure 17 depicts the ferrule installation device of figure 9 in the inserted state;

Figure 18 is a perspective view of a ferrule boot installation device in accordance with the principles of the present disclosure shown in a pre-inserted state;

Figure 19 is a side view of the ferrule boot installation device of figure 18 with a fiber clamp of the ferrule boot installation device in a closed position; Figure 20 depicts the ferrule boot installation device of figure 18 in an intermediate state;

Figure 21 depicts the ferrule boot installation device of figure 18 in an inserted state;

Figure 22 is an enlarged view of a portion of figure 20;

Figure 23 is an exploded view of a multi-fiber connector having a multi- fiber ferrule, a ferrule boot and optical fibers suitable for being assembled using processes and devices in accordance with the principles of the present disclosure;

Figure 24 is a cross-sectional view of the multi-fiber optical connector of figure 23 shown assembled; and

Figure 25 is a cross-sectional view cut lengthwise through the multi-fiber ferrule of the fiber optic connector of figures 23 and 24.

DETAILED DESCRIPTION

Figures 23 and 24 depict an example multi -fiber optical connector 300 (e.g., an MPO connector) having a ferrule assembly that is one example of a type of ferrule assembly that can be processed in accordance with aspects of the present disclosure. The multi -fiber optical connector 300 includes a multi -fiber ferrule 302 (e.g., an MPO ferrule) that mounts within a connector body 304. A release sleeve 306 for disengaging the connector body 304 from a fiber optic adapter is retractably mounted on the connector body 304. A ferrule assembly mounts within the connector body 304. The ferrule assembly includes the ferrule 302, a ferrule boot 308, an alignment pin assembly 310 and a spring 312. The ferrule assembly is retained within the connector body 304 by a rear connector body 314. When assembled, the spring 312 biases the ferrule 302 in a forward direction relative to the connector body 304.

Figure 24 depicts the multi-fiber optical connector 300 of Figure 23 in an assembled configuration. As depicted at Figure 24, optical fibers 315 extend through the ferrule boot 308 and through openings 309 defined at the front of the ferrule 302. As shown at Figure 25, the ferrule also defines internal grooves 311 (u-shaped or v-shaped grooves) immediately behind the openings 309 for facilitating directing (e.g., guiding, introducing, etc.) optical fibers into the openings 309 during the fiber insertion process. The internal grooves 311 have open sides that face upwardly. The ferrule boot 308 is mounted within a rear portion of the ferrule 302. In certain examples, the ferrule boot 308 assists in containing epoxy within the ferrule 302. It will be appreciated that the epoxy can be injected or otherwise provided within the ferrule 302 for securing the optical fibers 315 within the ferrule 302.

In certain examples, the ferrule 302 can be constructed of a material such as a plastic, a metal or a ceramic. A common ceramic material used in the manufacture of ferrules includes zirconia. A common plastic material used for multi-fiber ferrules includes polyphenylene sulfide (PPS) and preferably includes glass filled PPS. The optical fibers can include single mode optical fibers or multi-mode optical fibers.

Figure 1 depicts an example process 20 in accordance with the principles of the present disclosure. The process 20 starts with step 22 in which optical fibers are secured in a fiber clip and a multi-fiber ferrule is secured in a ferrule clip. The process 20 then proceeds to step 24 where a ferrule boot is installed over the optical fibers at a boot installation station while the optical fibers are held by the fiber clip. The process then proceeds to step 26, at which the optical fibers are stripped at a fiber coating stripping station while the optical fibers are held by the fiber clip. Thereafter, at step 28, the optical fibers are cleaved at a fiber cleaving station while the fibers are held by the fiber clip. The optical fibers can be cleaved at a cleave length measured with respect to a reference feature on the fiber clip. Next, at step 30, the multi -fiber ferrule is installed on the fibers at a ferrule installation station while the optical fibers are held by the fiber clip and the multi- fiber ferrule is held by the ferrule clip. Preferably, the fiber clip and the ferrule clip couple together during the insertion process with the coupling between the clips being adapted to maintain a predetermined fiber protrusion distance at an end face of the multi -fiber ferrule. The coupling between the clips allows the clips to be removed from the ferrule installation station as a unit while the coupled clips continue to ensure that the predetermined fiber protrusion distance is maintained. The coupled clips can be used to move the ferrule and the fibers together to subsequent processing stations while maintaining the predetermined fiber protrusion distance. For example, the coupled clips can be used to move the assembled optical fibers and ferrule to a station in which an adhesive material such as epoxy is injected or otherwise introduced into the ferrule to bond the optical fibers in place upon curing of the adhesive. The coupled clips can be used to move the assembled optical fibers and ferrule to a curing station where the adhesive within the ferrule is cured. Thereafter, at step 32, ends of the optical fibers as well as the end of the ferrule can be further processed by techniques such as polishing, laser processing or plasma processing.

In one example, the predetermined fiber protrusion distance is less than or equal to 300 microns or less than or equal to 250 microns, or less than or equal to 200 microns, or less than or equal to 100 microns, or less than or equal to 50 microns.

The process 20 of Figure 1 is directed toward a process for manufacturing an optical fiber and ferrule assembly. In certain examples, the optical fiber and ferrule assembly can include a row of optical fibers secured within parallel fiber passages of a ferrule (e.g., see optical fibers 315 within passages of the ferrule 302 of the multi-fiber optical connector 300 of Figures 23 and 24). As shown at Figure 24, the fiber passages extend in a rear-to-front orientation through the ferrule 302 and include the fiber openings 309. The fiber openings 309 each have a front end at a front face 317 of the ferrule 302.

Referring back to Figure 1, the process 20 starts by securing optical fibers (e.g., fibers 315) in a fiber clip 40 (see Figures 3 and 4) and by securing a multi-fiber ferrule (e.g., ferrule 302) in a ferrule clip 500 (see Figures 5 and 6). Figures 9-22 show the optical fibers 315 secured within the fiber clip 40 with front end portions 46 projecting forwardly beyond the fiber clip 40. Figure 5 shows the multi-fiber ferrule 302 secured within the ferrule clip 500. The fiber clip 40 and the ferrule clip 500 can include a mechanical interface for coupling the fiber clip 40 and ferrule clip 500 axially together in an end-to-end configuration (e.g., see Figure 2).

Figures 9-22 show the optical fibers 315 secured in a row within a fiber clip 40. As shown at Figures 3 and 4, the fiber clip 40 includes a base 42 and a fiber retention cover 44. The fiber retention cover 44 is movable relative to the base 42 between a closed position and an open position (shown in Figures 3 and 4). When the fiber retention cover 44 is in the open position, the optical fibers 315 can be placed within a channel 45 defined through a length L of the base 42. A fiber organizer 47 pivots with the fiber retention cover 44 and cooperates with the fiber retention cover 44 to define a slot 49 for stacking the fibers 315 in a row. A resilient pad 51 can assist in retaining the optical fibers 315 in the row within the slot 49. Once the fibers 315 are loaded in the slot 49, the fiber retention cover 44 can be moved to the closed position (shown at Figures 2 and 3) in which the optical fibers 315 are clamped relative to the base 42 (e.g., between the pad 51 and a clamping surface 53 of the base 42). When clamped, front end portions 46 of the optical fibers 315 project forwardly beyond a front end 48 of the base 42. In certain examples, a fiber reference location 50 can be established relative to the optical fibers 315 on the fiber clip 40. For example, a front face of the fiber clip 40 can be used as the fiber reference location 50 with respect to ends of the optical fibers 315. The front end portions 46 of the optical fibers 315 can be cleaved to extend a cleave length distance D (see Figure 11) beyond the fiber reference location 50. The fiber retention cover 44 can be magnetically held or mechanically latched in the closed position.

Figures 5 and 6 show the ferrule clip 500 in a closed and open position. The ferrule clip 500 incudes a base 502 and a cover 504 pivotally connected to the base 502. The base 502 defines a ferrule nest 506 for receiving the ferrule 302. The cover 504 is pivoted relative to the base 502 to move the ferrule clip 500 between the closed and open positions. When the ferrule clip 500 is in the open position, the ferrule 302 can be manually loaded into and removed from the ferrule nest 506. When the cover 504 is in the closed position with the ferrule 302 in the ferrule nest 506, the cover 504 can clamp the ferrule 302 within the ferrule nest 506. The cover 504 can be magnetically held or mechanically latched in the closed position.

The ferrule clip 500 and the fiber clip 40 preferably have a mating coupling interface 501 (see Figures 7 and 8) that axially aligns the ferrule clip 500 and the fiber clip 40 relative to one another and couples the ferrule clip 500 and the fiber clip 40 together in an end-to-end relationship (see Figure 2). The mating coupling interface 501 can be defined between axial end faces of the fiber clip 40 and the ferrule clip 500 which oppose one another when the fiber clip 40 and ferrule clip 500 are coupled together. The mating coupling interface 501 couples the ferrule clip 500 and the fiber clip 40 together such that the ferrule clip 500 and the fiber clip 40 can be moved together as a unit from processing station to processing station. Preferably, the fiber clip 40 and the ferrule clip 500 are coupled together concurrently with the optical fibers 315 being inserted into the ferrule 302 and the coupling between the fiber clip 40 and ferrule clip 500 assists in retaining the optical fibers 315 at a fully inserted position with respect to the ferrule 302. In this way, the coupling of the fiber clip 40 and ferrule clip 500 retains the fibers 315 fully inserted within the ferrule 302 for subsequent processing at least until the optical fibers 315 are effectively bonded within the ferrule 302 by an adhesive such as epoxy.

In one example, the mating coupling interface 501 includes at least one alignment pin 508 carried by one of the fiber clip 40 or the ferrule clip 500 that is received within a corresponding alignment opening 510 defined by the other of the fiber clip 40 and the ferrule clip 500. Figure 7 shows alignment pin 508 mated with the alignment opening 510. In one example, mating coupling interface includes at least one permanent magnet 512 for magnetically coupling the fiber clip 40 and the ferrule clip together. Figure 8 shows permanent magnets 512 holding the fiber clip 40 and ferrule clip 500 together. In the depicted example, two of the alignment pins 508 are carried by the ferrule clip 500 and are received within two alignment openings 510 defined by the fiber clip 40. In the depicted example, each of the fiber clip 40 and the ferrule clip 500 include a corresponding permanent magnet 512 arranged with the poles oriented such that the magnets are attracted to one another when the clips are mated. In other example one of the fiber clip 40 and ferrule clip 500 can include a permanent magnet and the other can include a corresponding magnetic ferrous insert.

Once the optical fibers 315 have been secured within the fiber clip 40, the ferrule boot 308 can be inserted over the front end portions 46 of the optical fibers 315 at a boot installation station. Figures 18-22 depict an example ferrule boot installation station 52 (e.g., a ferrule boot installation device) in accordance with the principles of the present disclosure. The ferrule boot installation station 52 includes a fiber clip mounting location such as a fiber clip nest 54 and a ferule boot mounting location such as a boot nest 56. The ferrule boot installation station 52 includes a base 53 supporting a block 58 defining the clip nest 54 and a carrier 60 defining the boot nest 56. The carrier 60 is movable relative to the clip nest 54 to transition the boot installation station 52 between a non-inserted state (see Figures 18 and 19) and an inserted state (see Figure 21). The carrier 60 mounts on a linear guide 61 (e.g., a linear guide rail) that guides linear movement of the carrier 60 defining the boot nest 56 as the carrier 60 is slid to transition the boot installation station 52 between the pre-inserted and inserted state. The boot nest 56 is configured to receive the ferrule boot 308 of the multi-fiber optical connector 300. When the ferrule boot 308 is mounted within the boot nest 56, a through passage of the boot nest 56 is aligned parallel to the direction of linear movement of the carrier 60 as the carrier moves along the linear guide 61. An open passage of the ferrule boot 308 preferably faces toward the fiber clip nest 54.

The fiber clip nest 54 is configured to receive the fiber clip 40 such that the optical fibers 315 held by the fiber clip 40 are coaxially aligned with the through-passage of the ferrule boot 308 which is mounted within the boot nest 56. When the fiber clip 40 is mounted within the clip nest 54, the front end portions 46 of the optical fibers 315 preferably extend toward the carrier 60 and overhang an edge of the block 58.

The linear guide 61 guides linear relative movement of the boot installation station 52 along a slide axis 53 that intersects the clip nest 54 and the boot nest 56 from the pre-inserted state (Figures 18 and 19) in which the end portions 46 of the optical fibers 315 are offset from the ferrule boot 308 and the inserted state (Figure 21) in which the end portions 46 of the optical fibers 315 are inserted through the ferrule boot 308. The ferrule boot installation station also is positionable in an intermediate state (see Figures 20 and 22) between the pre-inserted state and the inserted state in which the end portions 46 of the fibers 315 are inserted into the ferrule boot 308 an insertion distance less than when the ferrule boot installation station 52 is in the inserted state.

A fiber clamp 520 is supported on the base 53 between the carrier 60 and the block 58 for clamping the end portions 46 of the optical fibers 315 when the fiber clip 40 is mounted at the fiber clip nest 54. The fiber clamp 520 is moveable between an open clamp position (see Figures 18 and 21) and a closed clamp position (see Figures 19 and 20). The fiber clamp 520 includes a cam surface 522 for causing the fiber clamp 520 to be forced from the closed clamp position toward the open clamp position when the ferrule boot installation station reaches the intermediate state as the ferrule boot installation device is in the process of being moved from the pre-inserted state to the inserted state. In this way, the fiber clamp 520 is automatically opened during the fiber insertion process to prevent the fiber clamp 520 from interfering with full insertion of the ferrule boot 308 over the fibers 315. Thus, the clamp initially clamps the fibers to hold the fibers in alignment with the passage through the ferrule to ensure the fibers are initially received within the passage, and then opens after the fibers are received within the passage of the ferrule boot to allow the ferrule boot to be fully inserted over the fibers and moved into contact with the fiber clip 40.

The fiber clamp 520 includes upper and lower clamp members 524, 526 positioned along the slide axis 53 at a location between the carrier 60 and the block 58.

The upper and lower clamp members 524, 526 are pivotally moveable relative to one another between the closed clamp position and the open clamp position. In the closed position, the fibers 315 can be clamped between a resilient pad 527 on the upper clamp member 524 and a clamping surface 529 on the lower clamp member 526. The lower clamp member 526 includes the cam surface 522. At least one linear guide 530 guides vertical movement of the lower clamp member 526 relative to the base between a raised state (see Figure 19) and a lowered state (see Figure 21). A spring 532 is provided for biasing the lower clamp member 526 toward the raised state. The carrier 60 is configured to engage the cam surface 522 of the lower clamp member 526 when the ferrule boot installation station 52 reaches the intermediate state (see Figure 20) as the ferrule boot installation station is in the process of being moved from the pre-inserted state to the inserted state. At the intermediate state, engagement between the carrier 60 and the cam surface 522 of the lower clamp member 526 causes the lower clamp member 526 to move from the raised state to the lower state which causes the carrier 60 to engage the upper clamp member 524 such that the upper clamp member 524 is forced to pivot upwardly away from the lower clamp member 526 causing the fiber clamp 520 to move from the closed clamp position toward the open clamp position.

To install the ferrule boot 308 over the front end portions 46 of the optical fibers 315, the ferrule boot installation station 52 is moved to the pre-inserted state as shown at Figure 18, and then the ferrule boot 308 is loaded into the boot nest 56 and the fiber clip 40 is loaded into the clip nest 54. The carrier 60 is then moved toward the block 58 from the pre-inserted state of Figures 18 and 19 through the intermediate state of Figure 20 to the inserted state of Figure 21. As the carrier 60 is moved from the pre-inserted state to the intermediate state, the end portions 46 of the optical fibers 315 are received within the through passage of ferrule boot 308 such that the ferrule boot 308 is effectively inserted over the end portions 46 of the optical fibers 315. At the intermediate state, the carrier 60 forces open the fiber clamp 520 to allow the carrier to pass through the cam surface 522 to reach the inserted state. In this way, the ferrule boot 308 is installed on the optical fibers 315 held by the fiber clip 40.

Once the ferrule boot 308 has been installed on the optical fibers 315 at the ferrule boot installation station 52, the fiber clip 40 is removed from the clip nest 54 thereby concurrently moving the ferrule boot 308 from the boot nest 56 as the ferrule boot 308 is carried with the optical fibers 315 held by the fiber clip 40.

The fiber clip 40 is next moved a coating stripping station where a fiber coating layer (e.g., an acrylate coating layer) is stripped from the end portions 46 of the optical fibers 315. It will be appreciated that the optical fibers typically include a core, a cladding layer surrounding the core, and a coating layer surrounding the cladding layer. It is desirable for the coating layer to be removed from the cladding layer prior to inserting the optical fibers into the ferrule 302. Thus, it is preferred for the portions of the optical fibers received within the passages (i.e., openings) of the ferrule 302 to be bare (e.g., to include only a core surrounded by a cladding layer).

After the optical fibers 315 have been stripped, the fiber clip 40 which holds the stripped optical fibers 315 is transferred to a cleaving station for cleaving of the optical fibers. An example cleaving station can include a mechanical cleaving station or a laser cleaving station. The fibers 315 can be cleaved such that the front portions 46 of the optical fibers 315 extend the cleave length distance D beyond the reference surface 50 of the fiber clip 40. The cleave length distance D can be selected such that when the fiber clip 40 and the ferrule clip 500 are coupled together with the reference surface 50 axially abutting a corresponding axial end of the ferrule clip 500, the optical fibers 315 project a predetermined projection distance beyond the front end face of the ferrule 302.

Figures 9-17 depict an example ferrule installation station 130 (e.g., a ferrule installation device) for installing the ferrule 302 on the pre-cleaved optical fibers 315. The ferrule installation station 130 includes a base 132 supporting upper and lower plates 131, 133 stacked one on top of the other. The upper plate 131 defines a fiber clip mounting location such as fiber clip nest 134. The ferrule installation station 130 also includes a carrier 136 in which a ferrule clip mounting location such as a ferrule clip nest 138 is incorporated. The fiber clip nest 134 is adapted for receiving the fiber clip 40 and the ferrule clip nest 138 is adapted for receiving the ferrule clip 500. The carrier 136 is movable relative to the base along a slide axis 142 which intersects the fiber clip nest 134 and the ferrule clip nest 138 thereby enabling the ferrule installation station to be moved between a pre-inserted state (Figures 9-12) in which the end portions 46 of the optical fibers 315 are co-axially aligned but axially offset from the fiber openings 309 of the ferrule 302 and an inserted state (see Figures 13, 14 and 17) in which the end portions 46 of the fibers 315 are inserted within the fiber openings 309 of the ferrule 302. A linear guide 140 is provided for guiding movement of the carrier 136 linearly between pre inserted and inserted positions corresponding respectively to the pre-inserted and inserted states. The mating coupling interface 51 between the fiber clip for and the ferrule clip 500 aligns the ferrule clip 500 and the fiber clip 40 relative to one another and automatically couples the ferrule clip 500 and the fiber clip 40 together when the ferrule installation station 130 is moved from the pre-inserted state to the inserted state. The mating coupling interface 51 couples the ferrule clip 500 and the fiber clip 40 together such that the ferrule clip 500 and the fiber clip 40 can be removed from the ferrule installation device as a unit after the optical fibers have been inserted into the multi -fiber ferrule. The mating coupling interface 51 also retains the fibers 315 in an inserted position with respect to the ferrule 302 in which the fibers project a predetermined distance beyond the front face of the ferrule. It will be appreciated that the predetermined distance of fiber protrusion is established by the cleave length distance D of the fibers set with respect to the reference surface 50 of the fiber clip 40 during pre-cleaving of the fibers 315.

Linear movement of the carrier 136 defining the ferrule clip nest 138 is along a first dimension 139 (see Figure 15) parallel to the fiber openings of the ferrule 302 and the optical fibers 315. The fiber clip nest 134 is moveable along a second dimension 141 (see Figure 15) perpendicular with respect to the first dimension to allow the fiber end portions 46 to be moved along the second dimension 141 when the ferrule installation station is at an intermediate state (see Figures 15 and 16) between the pre-inserted state towards the inserted state. The fiber clip nest 134 is moveable along the second dimension 141 between a raised position (see Figure 15) and a lowered position (see Figure 16). The fiber clip nest 134 is spring biased by spring 143 toward the raised position. In one example, the fiber clip nest 134 is defined by the upper plate 131 which is guided between the raised and lower positions relative to the base by a linear guide arrangement including a vertical guide 135 received within a vertical guide opening 137 of the lower plate 133. In the depicted example, multiple vertical guides 135 and vertical guide openings 137 are provided.

The ferrule installation station 130 also includes a stop arrangement 151 for stopping linear movement between the ferrule clip nest 138 (e.g., the carrier 136) and the fiber clip nest 134 (e.g., the upper and lower plates 131, 133) at the intermediate state (see Figure 15) between the pre-inserted state and the inserted state when the fiber clip nest 134 is in the raised position and the ferrule installation station 130 is moved from the pre inserted state toward the inserted state. In the intermediate state, the end portions 46 of the optical fibers 315 are positioned over the alignment grooves 311 of the multi-fiber ferrule 302 and are not yet in received the fiber openings 309 of the multi -fiber ferrule 302. The ferrule installation station 130 can be moved from the intermediate state to the inserted state by moving the fiber clip nest 134 to the lowered position (see Figure 16) to clear the stop arrangement 151 thereby enabling the ferrule installation station 130 to be moved linearly from the intermediate state to the inserted state (see Figure 17).

In the depicted example, the stop arrangement 151 includes a pin 153 projecting from the fiber clip nest 134 defining structure (e.g., the upper plate 131) that is vertically offset from a receiving opening 155 defined by the ferrule clip nest defining structure (e.g., the carrier) when the fiber clip nest 134 defining structure is in the raised position. The pin 153 aligns with the receiving opening 155 when the fiber clip nest 134 defining structure is in the lowered position such that the pin 153 can fit within the opening 155 to allow the ferrule installation station 130 to be moved from the intermediate state of Figure 15 to the inserted state of Figure 16. In alternative example, the pin 153 can be provided on the ferrule clip nest defining structure and the opening 155 can be defined by the fiber clip nest defining structure. To use the ferrule installation station 130 to install the ferrule 302 on the optical fibers 315, the ferrule installation station 130 is initially moved to the pre-inserted state as shown at Figures 9-12. With the ferrule installation station 130 in the pre-inserted state, the ferrule clip 500 is loaded into the ferrule clip nest 138 of the carrier 136 and the fiber clip 40 holding the cleaved optical fibers 315 is loaded into the fiber clip nest 134. It will be appreciated that the fiber clip nest 134 and the ferrule clip nest 138 are relatively positioned in linear alignment such that fiber openings 309 of the ferrule 302 are co axially aligned with the optical fibers 315 held by the fiber clip 40. As shown at Figure 11, the end portions 46 of the optical fibers 315 project forwardly from the fiber clip 40 toward the ferrule 302 secured with the ferrule clip 500 mounted on the carrier 136. Although not depicted, the ferrule boot 308 can also be positioned on the front end portions 46 of the fibers 315. Via the relative positioning of the fiber clip nest 134 and the ferrule clip nest 138, the optical fibers 315 are co-axially aligned with the fiber openings of the ferrule 302. Therefore, by moving the carrier 136 from the pre-inserted position linearly through the intermediate position to the inserted position, the front end portions 46 of the optical fibers 315 are received within the fiber openings 309 of the ferrule 302 and the ferrule boot 308 is received within a rear opening of the ferrule 302. With the carrier 136 in the inserted position, the optical fibers 315 extend through the ferrule 302 and tip portions of the optical fibers 315 project the desired fiber projection length beyond the front face 317 of the ferrule 302. The fiber clip 40 and the ferrule clip 500 automatically couple together when the ferrule installation station 130 reaches the inserted state with the coupling between the clips maintaining the fiber tips at the desired projection length. Pressing down the fibers 315 into the internal grooves 311 at the intermediate state ensures the end portions 46 of the optical fibers 315 properly align with their corresponding fiber openings 309 in the ferrule 302 at the time the fibers 315 are inserted into the openings 309. The coupling between the fiber clip 40 and the ferrule clip 500 allows the fiber clip 40 and the ferrule clip 500 to be removed from the ferrule insertion station 130 as a unit and moved to subsequent processing station (e.g., an epoxy injection and curing station) while maintaining the desired fiber tip projection length at the end face of the ferrule.

It will be appreciated that the optical fiber can be cleaved by a mechanical cleaving process or a laser cleaving process. Example mechanical cleaving processes typically score the optical fibers at the desired cleave location, and then either flex or axially tension the optical fibers to cause the optical fibers to break at the scored location. In certain examples, the cleaved ends of the optical fibers as well as the front face of the ferrule can be further processed after the optical fibers have been secured within the ferrule. For example, the end face of the ferrule and the ends of the optical fibers can be subject to one or more subsequent polishing operations. However, by pre-cleaving the optical fibers and then positioning the cleaved ends in front of the end face of the ferrule, the cleaved ends can be positioned in relatively close proximity to the front face of the ferrule. For example, the cleaved end can be positioned within 250 microns, 200 microns, 100 microns, 50 microns, 20 microns, or 15 microns, or 12 microns, or 10 microns, of 5 microns of the front end face of the ferrule. Therefore, because the protrusion length of the optical fiber is relatively small, in certain examples, a reduced number of polishing steps may be utilized thereby reducing cost as compared to conventional processes for manufacturing optical fiber end ferrule assemblies. In certain examples, the ferrule itself can be pre-manufactured with a desired geometry or shape (e.g., molded to a desired shape) thereby further reducing the amount of processing required of the optical fiber and ferrule assembly after securement of the optical fibers within the ferrule.

Other aspects of the present disclosure relate to fiber holding devices such as fiber holding clips adapted for holding one or more optical fibers. In a preferred example, the present disclosure relates to fiber optic clips adapted to hold a plurality of optical fibers in a row. In certain examples, the fiber optic holding clip can hold the optical fibers in the row as the optical fibers are moved to different processing stations of a connector manufacturing process. In certain examples, the fiber holding clip can be adapted to be received within clip receivers (e.g., nests) in any number of different fiber processing stations such as optical fiber stripping stations, optical fiber cleaving stations, ferrule boot insertion stations and ferrule insertion stations. In other examples, the fiber holding clip can be configured to be mounted within an adapter that fits within any number of different fiber processing stations such as optical fiber stripping stations, optical fiber cleaving stations, ferrule boot insertion stations and ferrule insertion stations.

In certain examples, the fiber holding clips in accordance with the principles of the present disclosure can hold a plurality of optical fibers in a row with end portions of the optical fibers projecting forwardly beyond an end of the fiber holding clip. It will be appreciated that the end portions can be presented for processing at any number of different fiber processing stations as the optical fibers remain held by the fiber holding clip. For example, coatings of the optical fibers can be stripped from the end portions of the optical fibers at an optical fiber stripping station while the fiber holding clip holds the optical fibers. Similarly, the end portions of the optical fibers can be cleaved at an optical fiber cleaving station while the optical fibers remain held by the fiber holding clip.

Further, after stripping and cleaving, a ferrule boot can be inserted over the end portions of the optical fibers at a ferrule boot insertion station while the optical fibers remain held in a row by the fiber holding clip. Further, after the ferrule boot has been inserted over the end portions of the optical fibers at the ferrule boot insertion station, a ferrule can be inserted over the end portions of the optical fiber and over the ferrule boot at a ferrule insertion station while the fiber holding clip holds the optical fibers and positions the ferrule boot.

In other examples, the boot can be inserted installed on the optical fiber prior to stripping and/or cleaving of the optical fibers. As used herein, structures such as carriers, blocks, plates or the like can also be referred to as nest defining structures or mounting structures defining mounting locations for ferrule clips, fiber clips or ferrule boots. In alternative examples, sliding movement of the nest defining features can be reversed such that the features defining the fiber clip nests slide along an insertion axis and the features defining the ferrule clip nest or the ferrule boot nest remain stationary along the insertion axis.

From the forgoing detailed description, it will be evident that modifications and variations can be made without departing from the spirit and scope of the disclosure.

Claims

CLAIMS:

1. A system for processing fiber optic connectors, the system comprising: a ferrule clip for holding a multi-fiber ferrule defining a plurality of fiber openings arranged in a row with the fiber openings separated by a center-to-center spacing; a fiber clip for holding a plurality of optical fibers at the same center-to-center spacing as the fiber openings with end portions of the optical fibers projecting outwardly from the fiber clip; a ferrule installation device including a ferrule clip mounting location for mounting the ferrule clip and a fiber clip mounting location for mounting the fiber clip, the ferrule and fiber clip mounting locations being positioned such that when the ferrule clip and the fiber clip are mounted therein the optical fibers held by the fiber clip align with the fiber openings of the multi -fiber ferrule; the ferrule installation device including a linear guide for guiding linear relative movement between the ferrule clip mounting location and the fiber clip mounting location from a pre-inserted state in which the end portions of the optical fibers are offset from the fiber openings and an inserted state in which the end portions of the optical fibers are inserted into the fiber openings of the multi-fiber ferrule; and the ferrule clip and the fiber clip having a mating coupling interface that aligns the ferrule clip and the fiber clip relative to one another and couples the ferrule clip and the fiber clip together when the ferrule installation device is moved from the pre-inserted state to the inserted state, wherein the mating coupling interface couples the ferrule clip and the fiber clip together such that the ferrule clip and the fiber clip can be removed from the ferrule installation device as a unit after the optical fibers have been inserted into the multi -fiber ferrule.

2. The system of claim 1, wherein the mating coupling interface includes at least one alignment pin carried by one of the fiber clip and the ferrule clip that is received within a corresponding alignment opening defined by the other of the fiber clip and the ferrule clip.

3. The system of claim 2, wherein the mating coupling interface includes at least one permanent magnet for magnetically coupling the fiber clip and the ferrule clip together.

4. The system of claim 1, wherein the multi -fiber ferrule includes grooves that co axially align with the fiber openings, wherein the linear movement between the fiber clip mounting location and the ferrule clip mounting location is along a first dimension parallel to the fiber openings and the grooves, and wherein the fiber clip mounting location is moveable along a second dimension perpendicular with respect to the first dimension to allow the fiber end portions to be pressed into the grooves when the ferrule installation device is at an intermediate state between the pre-inserted state towards the inserted state.

5. The system of claim 4, wherein the fiber clip mounting location is moveable along the second dimension between a raised position and a lowered position, wherein the fiber clip mounting location is spring biased toward the raised position, and wherein the system further comprises a stop arrangement for stopping linear movement between the fiber clip mounting location and the ferrule clip mounting location at the intermediate state between the pre-inserted state and the inserted state when the fiber clip mounting location is in the raised position and the ferrule installation device is moved from the pre-inserted state toward the inserted state, wherein in the intermediate state the end portions of the optical fibers are positioned over the alignment grooves and are not yet in received the fiber openings, and wherein the ferrule installation device can be moved from the intermediate state to the inserted state by moving the fiber clip mounting location to the lowered position to clear the stop arrangement thereby enabling the ferrule installation device to be moved linearly from the intermediate state to the inserted state.

6. The system of claim 5, wherein the stop arrangement includes a pin that is offset from a receiving opening when the fiber clip mounting location is in the raised position and that aligns with the receiving opening when the fiber clip mounting location is in the lowered position.

7. The system of claim 1, wherein the ferrule installation device includes: a base; a linear guide rail supported on the base; a carrier mounted on the guide rail, the carrier being linearly moveable along a horizontal dimension relative to the base along the guide rail, the carrier defining a nest forming the ferrule clip mounting location; first and second plates, the first plate being mounted on the base and the second plate being mounted on the first plate, the second plate defining a nest forming the fiber clip mounting location, the nest of the carrier and the nest of the second plate being aligned along a slide axis defined by the guide rail; at least one linear guide for guiding vertical movement of the first and second plates between a raised state and a lowered state; a spring for biasing the first and second plates toward the raised state; the carrier being moveable along the guide rail toward and away from the first and second plates to move the ferrule installation device between the pre-inserted state and the inserted state.

8. The system of claim 1, wherein when the fiber clip and the ferrule clip are coupled together the optical fibers are retained at a position in which the end portion of the optical fibers project outwardly from an end face of the ferrule by a predetermined distance.

9. The system of claim 8, wherein the predetermined distance is established by cleaving the optical fibers while the optical fibers are held by the fiber clip before the fiber clip and the ferrule clip are coupled together, wherein the optical fibers are cleaved at a cleave distance from a reference surface of the fiber clip that is selected to cause the optical fibers to project outwardly from the end face of the ferrule by the predetermined distance when the fiber clip and the ferrule clip are coupled together.

10. A system for processing fiber optic connectors, the system comprising: a fiber clip for holding optical fibers with end portions of the optical fibers projecting outwardly from the fiber clip; a ferrule boot installation device including: a fiber clip mounting location for mounting the fiber clip; a ferrule boot mounting location for mounting a ferrule boot; the ferrule boot installation device including a linear guide for guiding linear relative movement between the ferrule boot mounting location and the fiber clip mounting location from a pre-inserted state in which the end portions of the optical fibers are offset from the ferrule boot and an inserted state in which the end portions of the optical fibers are inserted through the ferrule boot, the ferrule boot installation device also being positionable in an intermediate state between the pre-inserted state and the inserted state in which the end portions of the fibers are inserted into the ferrule boot an insertion distance less than when the ferrule boot installation device is in the inserted state; and a fiber clamp positioned between the fiber clip mounting location and the ferrule boot mounting location for clamping the end portions of the optical fibers when the fiber clip is mounted at the fiber clip mounting location, the fiber clamp being moveable between an open clamp position and a closed clamp position, the fiber clamp including a cam surface for causing the fiber clamp to be forced from the closed clamp position toward the open clamp position when the ferrule boot installation device reaches the intermediate state as the ferrule boot installation device is in the process of being moved from the pre-inserted state to the inserted state.

11. The system of claim 10, wherein the ferrule boot installation device further includes: abase; a linear guide rail supported on the base; a carrier mounted on the guide rail, the carrier being linearly moveable along a horizontal dimension relative to the base along the guide rail, the carrier defining a nest forming the ferrule boot mounting location; a block mounted on the base and which defines a nest forming the fiber clip mounting location, the nest of the carrier and the nest of the second plate being aligned along a slide axis defined by the guide rail; the fiber clamp including upper and lower clamp members positioned along the slide axis at a location between the carrier and the block, the upper and lower clamp members being pivotally moveable relative to one another between the closed clamp position and the open clamp position, the lower clamp member including the cam surface; at least one linear guide for guiding vertical movement of the lower clamp member relative to the base between a raised state and a lowered state; a spring for biasing the lower clamp member toward the raised state; and the carrier being moveable along the guide rail to move the ferrule boot installation device between the pre-inserted state and the inserted state, the carrier being configured to engage the cam surface of the lower clamp member when the ferrule boot installation device reaches the intermediate state as the ferrule boot installation device is in the process of being moved from the pre-inserted state to the inserted state, wherein the engagement between the carrier and the cam surface of the lower clamp member causes the lower clamp member to move from the raised state to the lower state which causes the carrier to engage the upper clamp member such that the upper clamp member is forced to pivot upwardly away from the lower clamp member causing the fiber clamp to move from the closed clamp position toward the open clamp position.

12. A ferrule installation device comprising: a ferrule clip mounting location for mounting a ferrule clip and a fiber clip mounting location for mounting a fiber clip, the ferrule and fiber clip mounting locations being positioned such that when the ferrule clip and the fiber clip are mounted therein optical fibers held by the fiber clip align with fiber openings of a multi-fiber ferrule held by the ferrule clip; a linear guide for guiding linear relative movement between the ferrule clip mounting location and the fiber clip mounting location from a pre-inserted state in which end portions of the optical fibers are offset from the fiber openings and an inserted state in which the end portions of the optical fibers are inserted into the fiber openings of the multi -fiber ferrule; and wherein the linear movement between the fiber clip mounting location and the ferrule clip mounting location is along a first dimension parallel to the fiber openings and the optical fibers, and wherein the fiber clip mounting location is moveable along a second dimension perpendicular with respect to the first dimension to allow the fiber end portions to be moved along the second dimension when the ferrule installation device is at an intermediate state between the pre-inserted state and the inserted state.

13. The device of claim 12, wherein the fiber clip mounting location is moveable along the second dimension between a raised position and a lowered position, wherein the fiber clip mounting location is spring biased toward the raised position, and wherein the device further comprises a stop arrangement for stopping linear movement between the fiber clip mounting location and the ferrule clip mounting location at the intermediate state between the pre-inserted state and the inserted state when the fiber clip mounting location is in the raised position and the ferrule installation device is moved from the pre-inserted state toward the inserted state, wherein in the intermediate state the end portions of the optical fibers are positioned over alignment grooves of the multi-fiber ferrule and are not yet in received the fiber opening of the multi-fiber ferrule, and wherein the ferrule installation device can be moved from the intermediate state to the inserted state by moving the fiber clip mounting location to the lowered position to clear the stop arrangement thereby enabling the ferrule installation device to be moved linearly from the intermediate state to the inserted state.

14. The device of claim 13, wherein the stop arrangement includes a pin that is offset from a receiving opening when the fiber clip mounting location is in the raised position and that aligns with the receiving opening when the fiber clip mounting location is in the lowered position.

15. A clip system comprising: a ferrule clip for holding a multi-fiber ferrule defining a plurality of fiber openings arranged in a row with the fiber openings separated by a center-to-center spacing; a fiber clip for holding a plurality of optical fibers at the same center-to-center spacing as the fiber openings with end portions of the optical fibers projecting outwardly from the fiber clip; and the ferrule clip and the fiber clip having a mating coupling interface that aligns the ferrule clip and the fiber clip relative to one another and couples the ferrule clip and the fiber clip together, wherein the mating coupling interface couples the ferrule clip and the fiber clip together such that the ferrule clip and the fiber clip can be moved as a unit after the optical fibers have been inserted into the multi -fiber ferrule.

16. The clip system of claim 15, wherein the mating coupling interface includes at least one alignment pin carried by one of the fiber clip and the ferrule clip that is received within a corresponding alignment opening defined by the other of the fiber clip and the ferrule clip.

17. The clip system of claim 16, wherein the mating coupling interface includes at least one permanent magnet for magnetically coupling the fiber clip and the ferrule clip together.

18. The clip system of claim 15, wherein when the fiber clip and the ferrule clip are coupled together the optical fibers are retained at a position in which the end portion of the optical fibers project outwardly from an end face of the ferrule by a predetermined distance.

19. The system of claim 18, wherein the predetermined distance is established by cleaving the optical fibers while the optical fibers are held by the fiber clip before the fiber clip and the ferrule clip are coupled together, wherein the optical fibers are cleaved at a cleave distance from a reference surface of the fiber clip that is selected to cause the optical fibers to project outwardly from the end face of the ferrule by the predetermined distance when the fiber clip and the ferrule clip are coupled together.