EXPANDED BEAM ARRAY FOR FIBER OPTICS

• US 20150104135A1
• Filed: 10/14/2014
• Published: 04/16/2015
• Est. Priority Date: 10/15/2013
• Status: Active Grant

• Current Assignee: Commscope Inc of North Carolina (CommScope Holding Company, Inc.)
• Original Assignee: Commscope Inc of North Carolina (CommScope Holding Company, Inc.)
• Inventors: NIELSON, Jeffrey D., Bushnell, Brian K., LOWE, Scott L.
• Granted Patent: US 10,162,127 B2
• Time in Patent Office: Days
• US Class Current: 385/79
• CPC Class Codes: G02B 6/325 comprising a transparent member, e.g. window, protective plate
• CPC Class Codes: G02B 6/3863 fabricated by using polishing techniques grinding of the fibre ends B24B19/226
• CPC Class Codes: G02B 6/3885 Multicore or multichannel optical connectors, i.e. one single ferrule containing more than one fibre, e.g. ribbon type optical ribbon cable G02B6/4403, G02B6/448

Abstract

An expanded beam fiber optic array connector includes a ferrule holding ends of optical fibers in a first ordered array. A plurality of lenses packaged into a unitary structure, formed of an optical grade material, different than a material used to form the ferrule, is attached to the ferrule. The lenses are arranged into a second ordered array matching the first ordered array of the ends of the optical fibers. The lenses of the expanded beam connector associated with transmit channels can be constructed with a prescription geared specifically for transmitting light, whereas the lenses of the expanded beam connector associated with receive channels can be constructed with a prescription geared specifically for receiving light.

Claims

1. A fiber optic ferrule comprising:

a first part for holding a plurality of optical fibers, said first part having a first end and a second end, wherein said second end is opposite to said first end;

a plurality of optical fibers entering at said first end of said first part and extending to said second end of said first part, wherein ends of said plurality of optical fibers are approximately flush or slightly protruding along a surface defining said second end of said first part;

a second part having a first face and a second face, wherein said first face of said second part abuts said second end of said first part, and wherein said second face is opposite to said first face; and

a plurality of lenses formed in said second part, wherein each lens of said plurality of lenses overlies a flush or protruding end of one of said plurality of optical fibers.

2. The fiber optic ferrule of claim 1, wherein said plurality of lens includes lenses of different prescriptions.

3. The fiber optic ferrule of claim 2, wherein said plurality of lens includes a first set of lenses of a first prescription optimized to receive light from a fiber end and transmit light away from the lens and a second set of lenses of a second prescription optimized to receive light into the lens and focus light onto a fiber end.

4. The fiber optic ferrule of claim 1, wherein said first part is formed of a polymer impregnated with a material to provide strength and reduce the coefficient of thermal expansion of said first part.

5. The fiber optic ferrule of claim 1, wherein said second part is formed of fused silica, fused quartz, sapphire, silicon, other optical glasses or optical grade polymers.

6. The fiber optic ferrule of claim 1, further comprising:

a stiffening element attached to said second element and extending in a direction substantially perpendicular to a direction defined from said first face of said second part to said second face of said second part.

7. The fiber optic ferrule of claim 6, wherein said stiffening element is a rod, embedded within a material forming said second part.

8. The fiber optic ferrule of claim 1, wherein a first distance is defined from a first plane of said first end of said first part to a second plane of said second end of said first part, a second distance is defined from a third plane of said first face of said second part to a fourth plane of said second face of said second part, and wherein a sum of said first and second distances is about 8 mm.

9. The fiber optic ferrule of claim 1, further comprising:

an optical epoxy attaching each lens of said plurality of lenses to an end of one of said plurality of optical fibers.

10. The fiber optic ferrule of claim 1, further comprising:

a first hole formed in said first part for accepting a first guide pin;

a second hole formed in said first part for accepting a second guide pin;

a third hole formed in said second part for accepting the first guide pin;

a fourth hole formed in said second part for accepting the second guide pin; and

a first guide pin passing through said first and third holes.

11. The fiber optic ferrule of claim 10, wherein said third hole includes at least one protruding surface formed on its perimeter extending toward a center of said third hole to create a frictional engagement with said first guide pin.

12. The fiber optic ferrule of claim 11, wherein said first guide pin is attached within said first part and extends outwardly from said first hole through said third hole for engagement with another connector, and wherein the second guide pin is part of the other connector and extends through said fourth hole and into said second hole.

13. The fiber optic ferrule of claim 1, wherein said second part is formed of a bezel at least partially surrounding a lenses portion containing said plurality of lenses.

14. The fiber optic ferrule of claim 13, wherein a forward edge of said bezel defines said second face of said second part and extends further away from said second end of said first part than any part of said lenses portion, such that said plurality of lenses are recessed into said second face of said second part.

15. The fiber optic ferrule of claim 13, wherein an optical epoxy attaches each lens of said plurality of lenses to an end of one of said plurality of optical fibers, wherein said bezel is separable from said lens portion, and wherein said bezel is removed after said lens portion is affixed to said second end of said first part.

16. The fiber optic ferrule of claim 15, wherein said lens portion may be adjusted in its position relative to said bezel before curing said optical epoxy to attach each lens of said plurality of lenses to an end of one of said plurality of optical fibers.

17. A method of forming an expanded beam fiber optic array connector comprising:

inserting a plurality of optical fibers into a first end of a first part until ends of the plurality of optical fibers are approximately flush with or slightly protruding from a second end of the first part;

cleaving and/or polishing the ends of the plurality of optical fibers flush with or protruding from the second end of the first part;

abutting a second part over the polished ends of the plurality of optical fibers;

aligning lenses within the second part with the polished ends of the plurality of optical fibers; and

attaching the second part to the first part.

18. The method of claim 17, wherein attaching the second part to the first part is accomplished by frictionally engaging one or more holes formed in the second part to one or more pins passing through those holes.

19. The method of claim 17, wherein attaching the second part to the first part is accomplished by curing an epoxy residing between the first and second parts.

20. An expanded beam fiber optic array connector comprising:

a ferrule holding ends of optical fibers in a first ordered array; and

a plurality of lenses packaged into a unitary structure formed of an optical grade material, different than a material used to form said ferrule,

wherein said lenses are arranged into a second ordered array matching said first ordered array of said ends of said optical fibers, and

wherein said unitary structure is attached to said ferrule with said second order array of lenses overlying said first ordered array of said ends of said optical fibers.

21. The expanded beam fiber optic array connector of claim 20, wherein said plurality of lens includes lenses of different prescriptions.

22. A fiber optic ferrule comprising:

a frame for holding a plurality of optical fibers, said frame having a first end and a second end, wherein said second end is opposite to said first end;

a plurality of optical fibers entering at said first end of said frame and extending toward said second end of said frame;

a lenses section formed at said second end of said frame, said lenses section having a plurality of lenses, wherein each lens of said plurality of lenses overlies ends of one of said plurality of optical fibers, and wherein said plurality of lens includes lenses of different prescriptions.

23. The fiber optic ferrule of claim 22, wherein said frame and said lenses section are integrally formed of a common material.

24. The fiber optic ferrule of claim 22, wherein said plurality of lens includes a first set of lenses of a first prescription optimized to receive light from a fiber end and transmit light away from the lens and a second set of lenses of a second prescription optimized to receive light into the lens and focus light onto a fiber end.

25. The fiber optic ferrule of claim 24, wherein lenses of said first set of lenses alternate with lenses of said second set of lenses in a single row.

26. The fiber optic ferrule of claim 24, wherein lenses of said first set of lenses are located in a first row and lenses of said second set of lenses are located in a second row.