Methods for processing ferrules and/or optical fibers
First Claim
Patent Images
1. A method for processing an optical fiber and for securing the optical fiber to a ferrule, the ferrule including a ferrule body having a distal end and a proximal end, the ferrule body also defining a fiber opening that extends axially through the ferrule body from the proximal end to the distal end, the method comprising:
- (a) processing a distal end face of the optical fiber so as to round and shape the distal end face of the optical fiber to form a pre-processed end face of the optical fiber;
(b) applying adhesive within the fiber opening of the ferrule body;
(c) inserting the optical fiber with the pre-processed end face through the adhesive filled opening of the ferrule body and positioning the optical fiber within the fiber opening such that the pre-processed end face of the optical fiber is located at a pre-determined axial position relative to the distal end of the ferrule body;
(d) curing the adhesive to fix the optical fiber within the fiber opening such that the pre-processed end face of the optical fiber is fixed at the pre-determined axial position relative to the distal end of the ferrule body; and
(e) removing excess adhesive from the pre-processed end face of the optical fiber using a non-contact energy source.
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Abstract
The present disclosure relates generally to methods for processing ferrules of fiber optic connectors such that the amount of polishing that is required is eliminated or at least reduced. In one example, an energy source is used to remove excess adhesive from the end face of the fiber and likely from an end face of the ferrule.
37 Citations
40 Claims
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1. A method for processing an optical fiber and for securing the optical fiber to a ferrule, the ferrule including a ferrule body having a distal end and a proximal end, the ferrule body also defining a fiber opening that extends axially through the ferrule body from the proximal end to the distal end, the method comprising:
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(a) processing a distal end face of the optical fiber so as to round and shape the distal end face of the optical fiber to form a pre-processed end face of the optical fiber; (b) applying adhesive within the fiber opening of the ferrule body; (c) inserting the optical fiber with the pre-processed end face through the adhesive filled opening of the ferrule body and positioning the optical fiber within the fiber opening such that the pre-processed end face of the optical fiber is located at a pre-determined axial position relative to the distal end of the ferrule body; (d) curing the adhesive to fix the optical fiber within the fiber opening such that the pre-processed end face of the optical fiber is fixed at the pre-determined axial position relative to the distal end of the ferrule body; and (e) removing excess adhesive from the pre-processed end face of the optical fiber using a non-contact energy source. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18)
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19. A method for processing an optical fiber and for securing the optical fiber to a ferrule, the ferrule including a ferrule body having a distal end and a proximal end, the ferrule body also defining a fiber opening that extends axially through the ferrule body from the proximal end to the distal end, the method comprising:
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(a) processing a distal end face of the optical fiber so as to round and shape the distal end face of the optical fiber to form a pre-processed end face of the optical fiber; (b) applying adhesive within the fiber opening of the ferrule body; (c) inserting the optical fiber with the pre-processed end face through the adhesive filled opening of the ferrule body and positioning the optical fiber within the fiber opening such that the pre-processed end face of the optical fiber is located at a pre-determined axial position relative to the distal end of the ferrule body; (d) curing the adhesive to fix the optical fiber within the fiber opening such that the pre-processed end face of the optical fiber is fixed at the pre-determined axial position relative to the distal end of the ferrule body; (e) removing excess adhesive from the pre-processed end face of the optical fiber using a non-contact energy source; (f) determining an initial core offset distance of an optical fiber core; and (g) polishing an end face of the ferrule at an 8 degree angle relative to the initial core offset distance of the optical fiber core.
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20. A method for processing an optical fiber and for securing the optical fiber to a ferrule, the optical fiber including a beam expansion section, the beam expansion section having a construction adapted to expand an optical beam from a first beam diameter to an enlarged second beam diameter, the ferrule including a ferrule body having a distal end and a proximal end, the ferrule body also defining a fiber opening that extends axially through the ferrule body from the proximal end to the distal end, the method comprising:
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(a) processing a distal end face of the optical fiber to form an optical fiber with a pre-processed end face; (b) applying adhesive within the fiber opening of the ferrule body; (c) inserting the optical fiber with the pre-processed end face through the adhesive filled opening of the ferrule body and retracting the optical fiber back into the fiber opening of the ferrule such that the beam expansion section is recessed relative to the distal end of the ferrule; (d) removing excess adhesive from the distal end of the ferrule; (e) establishing a position of the optical fiber such that the beam expansion section is protruding from the end face of the ferrule; (f) setting a recess distance of an optical fiber tip relative to the distal end of the ferrule; (g) curing the adhesive to fix the optical fiber within the fiber opening such that the beam expansion section is fixed relative to the distal end of the ferrule body; and (h) removing excess adhesive from the pre-processed end face of the optical fiber using a non-contact energy source. - View Dependent Claims (21, 22)
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23. A method for processing a ferrule assembly, the ferrule assembly including an optical fiber adhesively secured within a fiber opening defined by a ferrule, the method comprising:
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(a) at least partially filling the fiber opening of the ferrule with adhesive; (b) inserting the optical fiber into the fiber opening containing the adhesive; (c) curing the adhesive to secure the optical fiber within the ferrule; and (d) removing excess adhesive from a distal end of the optical fiber and/or from a distal end face of the ferrule using a non-contact energy source, wherein the step of removing excess adhesive from a distal end of the optical fiber and/or from a distal end face of the ferrule does not change a position of the distal end of the optical fiber relative to the distal end face of the ferrule. - View Dependent Claims (24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40)
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Specification