Unitary Multi-Fiber Optical Ferrule with Integrated Lenses

• US 20120093462A1
• Filed: 10/19/2010
• Published: 04/19/2012
• Est. Priority Date: 10/19/2010
• Status: Active Grant

• Current Assignee: US Conec Limited (Corning Incorporated)
• Original Assignee: US Conec Limited (Corning Incorporated)
• Inventors: Childers, Darrell R., Childers, Eric
• Granted Patent: US 9,563,027 B2
• Time in Patent Office: Days
• US Class Current: 385/33
• CPC Class Codes: G02B 6/382 with index-matching medium between light guides provisionally see G02B6/4212
• CPC Class Codes: G02B 6/3831 comprising a keying element on the plug or adapter, e.g. to forbid wrong connection keying element on the ferrule G02B6/3851; keying element for electrical coupling H01R13/64
• CPC Class Codes: G02B 6/3839 for a plurality of light guides
• CPC Class Codes: G02B 6/3853 Lens inside the ferrule lensed connectors G02B6/32
• CPC Class Codes: G02B 6/3855 characterised by the method of anchoring or fixing the fibre within the ferrule G02B6/3854 takes precedence
• CPC Class Codes: G02B 6/3861 Adhesive bonding adhesives in general C09J
• CPC Class Codes: G02B 6/3882 using rods, pins or balls to align a pair of ferrule ends
• CPC Class Codes: G02B 6/403 of the ferrule type, connecting a pair of ferrules
• CPC Class Codes: G02B 6/4403 with ribbon structure G02B6/4429, G02B6/4439, G02B6/4479 take precedence

Abstract

A unitary multi-fiber ferrule has micro-holes for optical fibers, an optical stop plane for the optical fibers, and a plurality of lenses disposed adjacent the front end, each of the plurality of lenses optically aligned with one of the micro-holes and exposed to air. Multiple rows of optical fibers and lenses may also be used in the unitary multi-fiber ferrule. The unitary multi-fiber ferrule requires less processing and equipment than other current optical ferrules.

Claims

1. A unitary fiber optic ferrule comprising:

a unitary main body having a front end, a back end, and a middle portion disposed between the front end and back end;

a first opening adjacent the back end of the unitary main body, the first opening configured to receive at least two optical fibers;

a plurality of optical fiber openings extending from the first opening toward the front end, each of the plurality of optical fiber openings configured to receive an optical fiber;

an optical fiber stop plane disposed between the plurality of optical fiber openings and the front end; and

a plurality of lenses disposed adjacent the front end, each of the plurality of lenses being in optical alignment with a respective one of the optical fiber openings, the plurality of lenses having at least one surface exposed to air.

2. The unitary fiber optic ferrule according to claim 1, further comprising at least one opening in an upper surface of the unitary main body to allow access to optical fibers inserted into the first opening.

3. The unitary fiber optic ferrule according to claim 1, further comprising a recessed portion directly adjacent the front end, the plurality of lenses disposed in the recessed portion.

4. The unitary fiber optic ferrule according to claim 1, further comprising a second opening disposed in the middle portion and in communication with the optical fiber stop plane.

5. The unitary fiber optic ferrule according to claim 1, wherein the main body is molded from an optically clear material.

6. The unitary fiber optic ferrule according to claim 1, wherein the at least two optical fibers are in an optical fiber ribbon.

7. The unitary fiber optic ferrule according to claim 1, wherein the at least two optical fibers comprise twelve optical fibers.

8. The unitary fiber optic ferrule according to claim 1, further comprising alignment features, the alignment features being selected from the group including guide pins, holes, and a combination of guide pins and holes.

9. The unitary fiber optic ferrule according to claim 1, wherein the front end functions as a physical stop for a mating fiber optic ferrule.

10. The unitary fiber optic ferrule according to claim 1, wherein the plurality of optical fiber openings and the plurality of lenses lie in a single plane.

11. The unitary fiber optic ferrule according to claim 1, wherein the plurality of optical fiber openings and the plurality of lenses lie in at least two planes.

12. The unitary fiber optic ferrule according to claim 1, wherein the front end has a fiber optic guide pin integrally formed with the unitary main body and extending outwardly from the front end.

13. The unitary fiber optic ferrule according to claim 12, wherein the front end has a fiber optic guide pin opening extending rearwardly therefrom to receive a corresponding fiber optic guide pin therein.

14. A unitary fiber optic ferrule comprising:

a unitary main body having a front end, a back end, and a middle portion disposed between the front end and back end;

a first opening adjacent the back end of the unitary main body, the first opening configured to receive at least two optical fibers;

a plurality of optical fiber openings extending from the first opening toward the front end, each of the plurality of optical fiber openings configured to receive an optical fiber;

a plurality of lenses disposed adjacent the front end, each of the plurality of lenses being in optical alignment with a respective one of the optical fiber openings, the plurality of lenses having at least one surface exposed to air; and

at least one fiber optic guide pin integrally formed with the unitary main body and extending outwardly from the front end.

15. The unitary fiber optic ferrule according to claim 14, wherein the front end has a fiber optic guide pin opening extending rearwardly therefrom to receive a corresponding fiber optic guide pin therein.

16. The unitary fiber optic ferrule according to claim 14, further comprising a recessed portion directly adjacent the front end, the plurality of lenses disposed in the recessed portion.

17. The unitary fiber optic ferrule according to claim 14, further comprising a second opening disposed in the middle portion and in communication with the optical fiber stop plane.

18. The unitary fiber optic ferrule according to claim 14, wherein the main body is molded from an optically clear material.

19. The unitary fiber optic ferrule according to claim 14, wherein the front end functions as a physical stop for a mating fiber optic ferrule.

20. The unitary fiber optic ferrule according to claim 14, wherein the plurality of optical fiber openings and the plurality of lenses lie in at least two planes.