Optical connector having a one-piece housing

• US 6,206,581 B1
• Filed: 03/13/2000
• Issued: 03/27/2001
• Est. Priority Date: 10/06/1999
• Status: Expired due to Term

• Current Assignee: Furukawa Electric North America Incorporated (Furukawa Electric Company Limited)
• Original Assignee: Lucent Technologies, Inc. (Nokia Corporation)
• Inventors: Driscoll, Elizabeth J., May, John Francis, Nielson, Jeffrey Dale, Lampert, Norman Roger, Subh, Naif Taleb
• Primary Examiner(s): Lee, John D.
• Assistant Examiner(s): HAHM, SARAH UH YOUNG
• Application Number:
  US09/524,335
• Time in Patent Office: 379 Days
• Field of Search: 385/53, 385/76, 385/78, 385/139, 385/92
• US Class Current: 385/78
• CPC Class Codes: G02B 6/3843 with auxiliary facilities for movably aligning or adjusting the fibre within its ferrule, e.g. measuring position or eccentricity testing the alignment of axes, including eccentricity, G01B11/27
• CPC Class Codes: G02B 6/3851 Ferrules having keying or coding means
• CPC Class Codes: G02B 6/3869 Mounting ferrules to connector body, i.e. plugs
• CPC Class Codes: G02B 6/3893 Push-pull type, e.g. snap-in, push-on

Abstract

The present invention provides a connector for terminating an optical fiber. The connector comprises a one-piece housing, a ferrule assembly and an insert. The insert has keys formed thereon that are adapted to mate with keyways formed in the housing. The housing has a first opening formed therein that first receives the ferrule assembly and then the insert and a second opening opposite the first opening. The end of the ferrule assembly that holds the end of the optical fiber protrudes through the second opening. The insert has a flange thereon that has two oppositely located flat surfaces and two oppositely located keys. The keys each have a chamfered surface. The keys and the flat surfaces of the flange provide the flange with a substantially rectangular cross-section. The first opening formed in the housing has a substantially square cross-section. When the insert is inserted into the first end of the housing, the substantially square cross-section of the opening aligns with the oppositely located flat surfaces of the flange to thereby cause the keys of the flange to align with the keyways formed in the surfaces of the housing. The chamfered surfaces of the keys deflect the sides of the housing outwardly as the insert is inserted into the housing. The keys of the insert are then received by the keyways formed in the housing to lock the insert into place within the housing.

Claims

1. A connector for terminating an optical fiber, the connector comprising:

a ferrule assembly having a first end, a second end and an axial passageway extending from the first end to the second end, the second end of the ferrule assembly adapted to maintain an end of an optical fiber in a substantially fixed position with respect to the second end of the ferrule assembly, the optical fiber passing through the axial passageway of the ferrule assembly;

a housing having walls having exterior surfaces and internal surfaces that define a cavity adapted to receive the ferrule assembly, the housing including a deformable first opening for receiving the ferrule assembly and a second opening through which the second end of the ferrule assembly protrudes, the first and second openings of the housing being located at opposite ends of the housing and axially aligned, the first opening in the housing having a substantially rectangular shape having a first transverse dimension, said housing being made of a material sufficiently flexible to enable at least some of the walls defining said cavity in the housing to be flexed outwardly in directions transverse to the length of the housing to deform said first opening, the housing having a keying mechanism; and

an insert having a first opening formed in a first end thereof, a second opening formed in a second end thereof, and a passageway for allowing an optical fiber to pass through the insert, the second end of the insert adapted to engage the first end of the ferrule assembly, the insert comprising a keying mechanism having a second transverse dimension greater than said first transverse dimension, the insert being adapted to be secured to the housing by pressing the insert into the housing and deforming said first opening by flexing the housing walls outwardly until the keying mechanism of the insert interlocks with the keying mechanism of the housing, the keying mechanisms preventing the insert from being inadvertently removed from the housing or rotated within the housing when the keying mechanism of the insert is interlocked with the keying mechanism of the housing.

2. The connector of claim 1, wherein the keying mechanism of the insert comprises a flange integrally formed about the insert, the flange having a substantially rectangular cross-section, the flange comprising two oppositely located flat sides and two oppositely located keys, said keys defining said second transverse dimension, the keys corresponding to the keying mechanism of the housing, each of the keys having a chamfered surface, each key being separated from the other key by one of the flat sides of the flange, the keys and flat surfaces forming a configuration that defines the substantially rectangular cross-section, and wherein the keying mechanism of the housing comprises first and second keyways formed in said walls of the housing, the surfaces of the housing in which the keyways are formed being opposite each other, wherein when the insert is pressed into the first opening of the housing a predetermined distance, the chamfered surfaces of keys of the flange cause the surfaces of the housing in which the keyways are formed to be deflected away from each other, the keys of the flange locking into the keyways when the insert has been pressed a predetermined distance into the first opening of the housing, the cooperation of the keys and the corresponding keyways locking the insert in a substantially fixed position with respect to the housing.

3. The optical connector of claim 1, wherein the keying mechanism of the insert has a substantially rectangular cross-section, and wherein when the insert is inserted into the first opening of the housing, the substantially rectangular shape of the first opening of the housing aligns with the substantially rectangular cross-section of the keying mechanism of the insert to prevent rotation therebetween.

4. The connector of claim 1, wherein the housing further comprises:

a manually operated latch adapted to secure the housing to an associated adapter to thereby prevent unintended decoupling of the housing from the adapter, the latch being positioned on a single side surface of the housing and movable in a direction that is perpendicular to the axial passageway of the ferrule assembly, the latch comprising a cantilever beam having a fixed end positioned toward the second opening of the housing and a free end extending in a direction away from the fixed end and away from the second opening.

5. The connector of claim 4, wherein the housing has a locking mechanism located adjacent the first end of the housing for attaching a yoke to the housing, the yoke comprising a trigger having a fixed end attached to the yoke and a free end extending in a direction away from the fixed end, the yoke having a locking mechanism thereon adapted to interlock with the locking mechanism of the housing, wherein when the yoke is attached to the housing, the free end of the trigger of the yoke is in proximity with the free end of the latch of the housing, and wherein when the trigger is depressed, the free end of the trigger exerts a downward force on the free end of the latch thereby causing the housing to be decoupled from the associated adapter.

6. The connector of claim 1, wherein the housing is comprised of polyphenylsulfone.

7. The connector of claim 6, wherein the housing is comprised of RADEL®

R polyphenylsulfone.

8. The connector of claim 1, wherein the housing is approximately 20 mm. in length from the first opening of the housing to the second opening of the housing.

9. A connector for terminating an optical fiber, the connector comprising:

a ferrule assembly, the ferrule assembly having a first end, a second end and an axial passageway extending from the first end to the second end, the second end of the ferrule assembly adapted to maintain an end of an optical fiber in a substantially fixed position with respect to the second end of the ferrule assembly, the optical fiber passing through the axial passageway of the ferrule assembly;

a housing having walls having exterior surfaces and internal surfaces that define a cavity adapted to receive the ferrule assembly, the housing including a first opening for receiving the ferrule assembly and a second opening through which the second end of the ferrule assembly protrudes, the first and second openings of the housing being located at opposite ends of the housing, the first opening in the housing having a substantially rectangular shape having a first transverse dimension, said housing being made of a material sufficiently flexible to enable the housing to be flexed outwardly in the directions transverse to the length of the housing, the housing having a keying mechanism; and

an insert having a first opening formed in a first end thereof, a second opening formed in a second end thereof, and a passageway for allowing an optical fiber to pass through the insert, the second end of the insert adapted to engage the first end of the ferrule assembly, the insert comprising a keying mechanism having a second transverse dimension greater than said first transverse dimension, the insert being adapted to be secured to the housing by pressing the first into the housing by pressing the insert into the housing and flexing the housing outwardly until the keying mechanism of the insert interlocks with the keying mechanism of the housing, the keying mechanism preventing the insert from being inadvertently removed from the housing or rated within the housing when the keying mechanism of the insert is interlocked with the keying mechanism of the housing;

wherein the keying mechanism of the insert comprises a flange integrally formed about the insert, flange having a substantially rectangular cross-section, the flange comprising two oppositely located flat sides and two oppositely located keys, said keys defining said second transverse dimension, the keys corresponding to the keying mechanism of the housing, each of the keys having a chamfered surface, each key being separated from the other key by one of the flat sides of the flange, the keys and flat surfaces forming a configuration that defines the substantially rectangular cross-section, and wherein the keying mechanism of the housing comprises first and second keyways formed in said walls of the housing, the surfaces of the housing in which the keyways are formed being opposite each other, wherein when the insert is pressed into the first opening of the housing a predetermined distance, the chamfered surfaces of keys of the flange cause the surfaces of the housing in which they keyways are formed to be deflected away from each other, the keys of the flange locking into the keyways when the insert has been pressed a predetermined distance into the first opening of the housing, the cooperation of the keys and the corresponding keyways locking the insert in a substantially fixed position with respect to the housing; and

the insert has a first cylindrical portion extending from the first cylindrical portion extending from the first end of the insert to a circumferential stop integrally formed on the exterior surface of the insert, a second cylindrical portion extending from the stop to the flange, and a third cylindrical portion extending from the flange to the second end of the insert, and wherein when the insert is locked into position within the housing by the interlocking of the keys of the flange with the keyways of the housing, the stop abuts the first opening in the housing, the stop being larger in size than the first opening such that the first opening prevents the stop from entering the housing.

10. The connector of claim 9, wherein the insert is comprised of a brass alloy.

11. The connector of claim 9, wherein the insert is comprised of a stainless steel.

12. The connector of claim 9, wherein the insert is comprised of aluminum.

13. A connector for terminating an optical fiber, the connector comprising:

a ferrule assembly, the ferrule assembly having a first end, a second end and an axial passageway extending from the first end to the second end, the second end of the ferrule assembly adapted to maintain an end of an optical fiber in a substantially fixed position with respect to the second end of the ferrule assembly, the optical fiber passing through the axial passageway of the ferrule assembly;

a housing having walls having exterior surfaces and internal surfaces that define a cavity adapted to receive the ferrule assembly, the housing including a first opening for receiving the ferrule assembly and a second opening through which the second end of the ferrule assembly protrudes, the first and second openings of the housing being located at opposite ends of the housing, the first opening in the housing having a substantially rectangular shape having a first transverse dimension, said housing being made of a material sufficiently flexible to enable the housing to be flexed outwardly in directions transverse to the length of the housing, the housing having a keying mechanism; and

an insert having a first opening formed in a first end thereof, a second opening formed in a second end thereof, and a passageway for allowing an optical fiber to pass through the insert, the second end of the insert adapted to engage the first end of the ferrule assembly, the insert comprising a keying mechanism having a second transverse dimension greater than said first transverse dimension, the insert being adapted to be secured to the housing by pressing the insert into the housing and flexing the housing outwardly until the keying mechanism of the insert interlocks with the keying mechanism of the housing, the keying mechanism preventing the insert from being inadvertently removed from the housing or rotated within the housing when the keying mechanism of the insert is interlocked with the keying mechanism of the housing;

wherein the ferrule assembly comprises;

a barrel portion having a first end and a second end and an axial passageway formed therein, the second end of the barrel having a hexagonal cross-section;

a ferrule having a first end and a second end, the first end of the ferrule being fixedly secured to the second end of the barrel, the ferrule having an axial passageway formed therein for receiving said end of the optical fiber, said end of the optical fiber passing through the axial passageway of the barrel and through the axial passageway of the ferrule such that said end of the optical fiber is disposed in the second end of the ferrule; and

a flexible tube having a first end and a second end and an axial passageway formed therein, the second end of the tube being fixedly secured to the first end of the barrel, the optical fiber passing through the axial passageway of the tube.

14. The connector of claim 13, wherein the barrel is comprised of stainless steel, and wherein a buffer coating of an optical fiber cable comprising the optical fiber passing through the axial passageway of the ferrule assembly is adhesively attached to the barrel.

15. The connector of claim 13, further comprising:

a spring having a generally cylindrical shape, the spring being disposed about the tube of the ferrule assembly when the ferrule assembly is securing within the housing, the spring having a first end and a second end, wherein when the insert engages the ferrule assembly, the second end of the insert is inserted over the first end of the tube and is placed in contact with the first end of the spring, and wherein when the insert is fixedly secured within the housing by the locking of the keying mechanisms, the spring is preloaded and the second end of the spring is in contact with the second end of the barrel, the second end of the barrel preventing the second end of the spring from coming into contact with the ferrule, and wherein when the second end of the barrel is pushed in a direction from the second opening in the housing toward the first opening in the housing such that the second end of the barrel is not seated in the recess of the housing, the second end of the barrel is rotatable to enable an eccentricity parameter associated with the ferrule assembly to be tuned.

16. The connector of claim 15, wherein the housing further comprises:

an annular cylindrical portion having a first end and a second end, the first end of the annular cylindrical portion being adjacent the first opening of the housing; and

a recess having a hexagonal cross-section adapted to receive the second end of the barrel of the ferrule assembly, wherein when the ferrule assembly is secured within the housing, the second end of the barrel having the hexagonal cross-section is seated within the recess having the hexagonal cross section.

17. The connector of claim 16, wherein the insert has a circumferential groove formed adjacent the first end for attachment of strength members of an optical fiber cable to the insert, the circumferential groove being located between the first end of the insert and the circumferential stop.

18. For use in an optical fiber connector having a ferrule assembly and a cylindrical insert member having a flange thereon having keys defining a first transverse dimension, the flange having at least one flat portion thereon, a housing member for receiving the ferrule assembly and the insert member, said housing member comprising:

a one piece elongated member having a central bore extending therethrough, at least a portion of said bore having a polygonal cross-section for orienting the flat portion of the flange on the insert member;

said portion of said bore having a maximum transverse dimension less than the first transverse dimension of the flange on said insert whereby the flange distorts said housing when the insert is inserted therein; and

said housing member being made of a material sufficiently flexible to withstand the distortion.

19. A housing member as claimed in claim 18 wherein said material of said housing is polyphenylsulfone.

20. A housing member as claimed in claim 18 wherein said elongated member has exterior walls and at least one keyway extending from said bore through one of said exterior walls for receiving a key on the flange of the insert member.

21. A housing member as claimed in claim 20 and further including a second keyway extending through one of said exterior walls diametrically opposite said at least one keyway.