TOOLING AND METHOD FOR MANUFACTURING A FIBER OPTIC ARRAY

• US 20160041357A1
• Filed: 08/03/2015
• Published: 02/11/2016
• Est. Priority Date: 08/05/2014
• Status: Active Grant

• Current Assignee: CommScope Connectivity UK Limited (TE Connectivity Limited)
• Original Assignee: Tyco Electronics UK Limited (TE Connectivity Limited)
• Inventors: White, Gordon John, Taylor, Christopher Charles, Murray, David Patrick
• Granted Patent: US 9,829,667 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: G02B 6/3612 Wiring methods or machines
• CPC Class Codes: G02B 6/368 with pitch conversion between input and output plane, e.g. for increasing packing density
• CPC Class Codes: G02B 6/3897 Connectors fixed to housings, casing, frames or circuit boards G02B6/44528 takes precedence
• CPC Class Codes: G02B 6/406 of the ferrule type, connecting a plurality of pairs of ferrules
• CPC Class Codes: G02B 6/4403 with ribbon structure G02B6/4429, G02B6/4439, G02B6/4479 take precedence
• CPC Class Codes: G02B 6/44528 Patch-cords; Connector arrangements in the system or in the box routing arrangements H04Q1/00
• CPC Class Codes: G02B 6/4453 Cassettes
• CPC Class Codes: G02B 6/4471 Terminating devices demountable connectors G02B6/3807; Cable clamps
• CPC Class Codes: G02B 6/44715 Fan-out devices
• CPC Class Codes: G02B 6/4475 with provision for lateral branching G02B6/4431 takes precedence

Abstract

A fixture (44/244) is for forming a fiber optic array (10/110/210) that defines a plurality of discrete fibers (12) extending from a spaced-apart arrangement to a consolidated arrangement wherein the fibers (12) are layered next to each other for a further ribbonizing process. The fixture (44/244) includes a pair of contact blades (54/254) that are configured to slide along a direction transverse to the longitudinal axes of the fibers (12) for consolidating the fibers (12).

Claims

1. A fiber optic array (10/110), comprising:

a plurality of optical fibers (12);

a substrate (16) for supporting the plurality of optical fibers (12), the substrate (16) defining a first end (22) and a second end (24); and

a plurality of spaced-apart channels (26) defining parallel portions at the first end (22) of the substrate (16) and a fiber clamp (30) provided at the second end (24) of the substrate (16);

wherein the plurality of optical fibers (12) are positioned on the substrate (16) such that the fibers (12) extend from being spaced-apart via the channels (26) to a consolidated arrangement wherein the fibers (12) are layered next to each other, the fiber clamp (30) securing the consolidated fibers (12) at the second end (24) of the substrate (16).

2. A fiber optic array (10/110) according to claim 1, wherein the fiber clamp (30) is defined by a clip (32/132) that is snap-fit interlocked to the substrate (16).

3. A fiber optic array (10/110) according to claim 1, wherein the fibers (12) supported by the substrate (16) are further secured to the substrate (16) via at least one piece of adhesive tape (36/38).

4. A fiber optic array (10/110) according to claim 1, wherein the fibers (12) at the channels (26) extend outwardly from the channels (26) to an exterior of the substrate (16) to form pigtails, wherein the pigtails are terminated with fiber optic ferrules (18).

5. A fixture (44/244) for forming a fiber optic array (10/110/210) that defines a plurality of discrete fibers (12) extending from a spaced-apart arrangement to a consolidated arrangement wherein the fibers (12) are layered next to each other for a further ribbonizing process, the fixture (44/244) comprising:

a pair of contact blades (54/254) that are configured to slide along a direction transverse to the longitudinal axes of the fibers (12) for consolidating the fibers (12).

6. A fixture (44/244) according to claim 5, further defining channels (26/226) at a front end (46/246) thereof for supporting the fibers (12) in the spaced-apart arrangement.

7. A fixture (44/244) according to claim 6, wherein the channels (26/226) define curved rear portions (40/240) for transitioning the fibers (12) from the spaced-apart arrangement toward a consolidation point (28/228) at which the fibers (12) are to be layered next to each other for ribbonizing.

8. A fixture (44) according to claim 6, wherein the channels (26) are defined by a removable substrate (16) that forms a part of the fiber optic array (10/110) manufactured using the fixture (44).

9. A fixture (44/244) according to claim 5, wherein the fixture (44/244) includes at least one clamp (56/256, 257, 58/258, 60/260) for keeping the fibers (12) within the channels (26/226) in the spaced-apart arrangement.

10. A fixture (44/244) according to claim 9, wherein the at least one clamp (56/256, 257, 58/258, 60/260) includes a first clamp (56/256) adjacent a front end (46/246) of the fixture (44/244) for keeping the fibers (12) within the channels (26/226) and a second clamp (58/258) adjacent a rear end (48/248) of the fixture (44/244) for keeping the fibers (12) against a bearing surface (50/250) of the fixture (44/244) for contact by the transversely moving contact blades (54/254).

11. A fixture (44) according to claim 10, wherein the second clamp (58) is slidable in a direction from the rear end (48) of the fixture (44) toward the front end (46) of the fixture (44).

12. A fixture (44) according to claim 11, wherein the second clamp (58) defines a plurality of vertical pins (70), each pin (70) positioned to be in between a given pair (112) of fibers (12) such that if the fibers (12) of the given pair (112) are crossed-over, the pin (70) can contact both fibers (12) of the given pair (112) at a cross-over point (114) and move the cross-over point (114) toward the front end (46) of the fixture (44).

13. A method for forming a fiber optic array (10/110/210) that defines a plurality of discrete fibers (12) extending from a spaced-apart arrangement to a consolidated arrangement wherein the fibers (12) are layered next to each other for a further ribbonizing process, the method comprising:

laying the fibers (12) within spaced-apart channels (26/226) defined on a fixture (44/244), the channels (26/226) having parallel portions;

moving a pair of contact blades (54/254) on the fixture (44/244) along a direction transverse to the longitudinal axes of the fibers (12) to abut and to consolidate the fibers (12); and

securing together the fibers (12) at both the spaced-apart portion of the array (10/110/210) and the consolidated portion of the array (10/110/210).

14. A method according to claim 13, wherein the channels (26) are defined by a substrate (16) that is provided as a removable insert of the fixture (44) that carries the transversely moving contact blades (54).

15. A method according to claim 14, further comprising removing the substrate (16) from the fixture (44) after the spaced-apart portion and the consolidated portion of the fibers (12) have been secured to the substrate (16).

16. A method according to claim 13, wherein the fibers (12) are placed within the channels (26/226) such that portions thereof extend outwardly from the channels (26/226) to form pigtails, wherein the pigtails are terminated with fiber optic ferrules (18).

17. A method according to claim 13, further comprising ribbonizing the consolidated fibers (12).

18. A method according to claim 13, wherein the plurality of discrete fibers (12) define pairs (112) of fibers (12), the method further comprising crossing over the fibers (12) of each of the pairs (112) to form crossed-over fibers (12) before moving the contact blades (54) to consolidate the fibers (12).

19. A method according to claim 18, further comprising contacting both fibers (12) of a given pair (112) at a cross-over point (114) by a vertical pin (70) to move the cross-over point (114) toward the channels (26) defined on the fixture (44).

20. A method according to claim 13, further securing the formed fiber optic array (210) between two polymeric sheets to form a flexible optical circuit (200).