Preconnectorized fiber optic drop cables and assemblies

• US 7,090,406 B2
• Filed: 01/27/2004
• Issued: 08/15/2006
• Est. Priority Date: 05/26/2000
• Status: Expired due to Term

• Current Assignee: Corning Optical Communications LLC (Corning Incorporated)
• Original Assignee: Corning Cable Systems LLC (Corning Incorporated)
• Inventors: Gimblet, Michael J., Tran, Hieu V., Melton, Stuart R., Liu, Xin, Thompson, David A., Wagman, Richard S.
• Primary Examiner(s): Font, Frank G.
• Assistant Examiner(s): WONG, ERIC K
• Application Number:
  US10/765,428
• Publication Number:
  US 20040223720A1
• Time in Patent Office: 931 Days
• Field of Search: 385 78- 80, 385/62, 385/147
• US Class Current: 385/62
• CPC Class Codes: G02B 6/3821 with axial spring biasing or loading means G02B6/3847 takes precedence
• CPC Class Codes: G02B 6/3849 using mechanical protective elements, e.g. caps, hoods, sealing membranes G02B6/3816 takes precedence; provisionally see H01R13/44
• CPC Class Codes: G02B 6/3869 Mounting ferrules to connector body, i.e. plugs
• 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
• CPC Class Codes: G02B 6/38875 Protection from bending or twisting
• CPC Class Codes: G02B 6/3888 Protection from over-extension or over-compression
• CPC Class Codes: G02B 6/3889 using encapsulation for protection, e.g. adhesive, molding or casting resin
• CPC Class Codes: G02B 6/3894 Screw-lock type
• CPC Class Codes: G02B 6/3897 Connectors fixed to housings, casing, frames or circuit boards G02B6/44528 takes precedence
• CPC Class Codes: G02B 6/4405 with longitudinally spaced waveguide clamping G02B6/4429, G02B6/4439, G02B6/4479 take precedence
• CPC Class Codes: G02B 6/4429 Means specially adapted for strengthening or protecting the cables
• CPC Class Codes: G02B 6/4433 Double reinforcement laying in straight line with optical transmission element
• CPC Class Codes: G02B 6/44384 the means comprising water blocking or hydrophobic materials G02B6/4439, G02B6/4479 take precedence
• CPC Class Codes: G02B 6/46 Processes or apparatus adapted for installing or repairing optical fibres or optical cables installation of cables containing electric conductors and optical fibres H02G

Abstract

A preconnectorized outdoor cable streamlines the deployment of optical waveguides into the last mile of a optical network. The preconnectorized outdoor cable includes a cable and at least one plug connector. The plug connector is attached to a first end of the cable, thereby connectorizing at least one optical waveguide. The cable has at least one optical waveguide, at least one tensile element, and a cable jacket. Various cable designs such as figure-eight or flat cables may be used with the plug connector. In preferred embodiments, the plug connector includes a crimp assembly having a crimp housing and a crimp band. The crimp housing has two half-shells being held together by the crimp band for securing the at least one tensile element. When fully assembled, the crimp housing fits into a shroud of the preconnectorized cable. The shroud aides in mating the preconnectorized cable with a complimentary receptacle.

Claims

1. A preconnectorized outdoor cable comprising:

a cable, the cable having at least one optical waveguide and at least one tensile element, and a cable jacket, wherein the cable jacket generally surrounds the at least one optical waveguide and the at least one tensile element; and

at least one plug connector, the at least one plug connector being attached to a first end of the cable, thereby connectorizing at least one optical waveguide, the at least one plug connector comprising;

a crimp assembly, wherein the crimp assembly includes a crimp housing and a crimp band, wherein the crimp housing comprises two half-shells being held together by the crimp band, the two half-shells having a longitudinal passageway for passing the at least one optical fiber therethrough, at least one cable clamping portion, and a connector assembly clamping portion, wherein the at least one cable clamping portion secures the at least one tensile element; and

a connector assembly, the connector assembly includes a connector body and a ferrule, wherein a portion of the connector assembly is secured in the connector assembly clamping portion of the two half-shells of the crimp housing.

2. The preconnectorized outdoor cable of claim 1, the connector housing clamping portion being configured for securing more than one connector assembly.

3. The preconnectorized outdoor cable of claim 1, the at least one tensile element of the cable being a strength component having an anti-buckling strength characterisitic.

4. The preconnectorized outdoor cable of claim 1, the at least one tensile element of the cable being a strength member that essentially lacks an anti-buckling strength characteristic.

5. The preconnectorized outdoor cable of claim 1, the two half-shells having a curvilinear longitudinal passageway therethrough for routing the at least one optical waveguide.

6. The preconnectorized outdoor cable of claim 1, the at least one plug connector further comprising a shroud, the shroud having a keyed passageway for inhibiting rotation between the shroud and the crimp assembly.

7. The preconnectorized outdoor cable of claim 1, further comprising a coupling nut for removably attaching the at least one plug connector with a complementary mating receptacle.

8. The preconnectorized outdoor cable of claim 1, the connector assembly further including a ferrule holder.

9. The preconnectorized outdoor cable of claim 1, the at least one plug connector further comprising a shroud for protecting the connector assembly.

10. The preconnectorized outdoor cable of claim 9, the shroud defining a pair of openings on opposite sides of a first end, the opening extending lengthwise from a medial portion of the shroud to the first end of the shroud, wherein the ferrule is accessible within the first end of the shroud.

11. The preconnectorized outdoor cable of claim 9, further comprising a heat shrink tube for weatherproofing the preconnectorized outdoor cable, the heat shrink tube being disposed about a second end of the shroud and a portion of the cable jacket.

12. The preconnectorized outdoor cable of claim 9, the shroud having two fingers for mating with a complementary receptacle, wherein the two fingers are disposed about 180 degrees apart and have different cross-sectional shapes for keying the plug connector with the complementary receptacle.

13. The preconnectorized outdoor cable of claim 9, further comprising an O-ring disposed on the shroud for weatherproofing the at least one plug connector.

14. The preconnectorized outdoor cable of claim 1, the at least one plug connector further comprising a shroud having a first end and a second end, wherein the shroud has at least one alignment indicia for indicating a mating orientation.

15. The preconnectorized outdoor cable of claim 1, the at least one plug connector further comprising a shroud having a first end and a second end, the shroud has a plurality of fingers for mating with a complementary receptacle, wherein at least two of the fingers have different cross-sectional shapes for keying the plug connector with the complementary receptacle.

16. The preconnectorized outdoor cable of claim 1, the at least one plug connector having a protective cap and a retention wire, wherein the protective cap is attached to the at least one plug connector by a retention wire.

17. The preconnectorized outdoor cable of claim 1, a plurality of the components of the at least one plug connector being formed from a UV stabilized material.

18. The preconnectorized outdoor cable of claim 1, the at least one cable clamping portion having at least one rib for securing the at least one tensile element.

19. The preconnectorized outdoor cable of claim 1, the cable further comprising a dry insert being disposed within the cable jacket.

20. The preconnectorized outdoor cable of claim 1, the cable having at least one electrical conductor for transmitting power, the at least one electrical conductor being in electrical communication with an electrical terminal of the plug connector.

21. A preconnectorized outdoor cable comprising:

a cable, the cable having at least one optical waveguide and at least one tensile element, and a cable jacket, wherein the cable jacket generally surrounds the at least one optical waveguide and the at least one tensile element; and

at least one plug connector, the at least one plug connector being attached to a first end of the cable, thereby connectorizing at least one optical waveguide, wherein a plurality of the components of the at least one plug connector are formed from a UV stabilized material, the at least one plug connector comprising;

a crimp assembly, wherein the crimp assembly includes a crimp housing and a crimp band, wherein the crimp housing comprises two half-shells being held together by the crimp band, the two half-shells having a longitudinal passageway for passing the at least one optical fiber therethrough, at least one cable clamping portion, and a connector assembly clamping portion, wherein the at least one cable clamping portion secures the at least one tensile element of the cable; and

a connector assembly, the connector assembly includes a connector body and a ferrule, wherein a portion of the connector assembly is secured in the connector assembly clamping portion of the two half-shells of the crimp housing.

22. The preconnectorized outdoor cable of claim 21, the connector housing clamping portion being configured for securing more than one connector assembly.

23. The preconnectorized outdoor cable of claim 21, the at least one tensile element of the cable being a strength component having an anti-buckling strength characteristic.

24. The preconnectorized outdoor cable of claim 21, the at least one tensile element being a strength member that essentially lacks an anti-buckling strength characteristic.

25. The preconnectorized outdoor cable of claim 21, the two half-shells having a curvilinear longitudinal passageway therethrough for routing the at least one optical waveguide.

26. The preconnectorized outdoor cable of claim 21, the at least one plug connector further comprising a shroud, the shroud having a keyed passageway for inhibiting rotation between the shroud and the crimp assembly.

27. The preconnectorized outdoor cable of claim 21, further comprising a coupling nut for removably attaching the at least one plug connector with a complementary mating receptacle.

28. The preconnectorized outdoor cable of claim 21, the connector assembly further including a ferrule holder.

29. The preconnectorized outdoor cable of claim 21, the at least one plug connector further comprising a shroud for protecting the connector assembly.

30. The preconnectorized outdoor cable of claim 29, the shroud defining a pair of openings on opposite sides of a first end, the opening extending lengthwise from a medial portion of the shroud to the first end of the shroud, wherein the ferrule is accessible within the first end of the shroud.

31. The preconnectorized outdoor cable of claim 29, further comprising a heat shrink tube for weatherproofing the preconnectorized outdoor cable, the heat shrink tube being disposed about a second end of the shroud and a portion of the cable jacket.

32. The preconnectorized outdoor cable of claim 29, the shroud having two fingers for mating with a complementary receptacle, wherein the two fingers are disposed about 180 degrees apart and have different cross-sectional shapes for keying the plug connector with the complementary receptacle.

33. The preconnectorized outdoor cable of claim 29, further comprising an O-ring disposed on the shroud for weatherproofing the at least one plug connector.

34. The preconnectorized outdoor cable of claim 21, the at least one plug connector further comprising a shroud having a first end and a second end, wherein the shroud has at least one alignment indicia for indicating a mating orientation.

35. The preconnectorized outdoor cable of claim 21, the at least one plug connector further comprising a shroud having a first end and a second end, the shroud has a plurality of fingers for mating with a complementary receptacle, wherein at least two of the fingers have different cross-sectional shapes for keying the plug connector with the complementary receptacle.

36. The preconnectorized outdoor cable of claim 21, the at least one plug connector having a protective cap and a retention wire, wherein the protective cap is attached to the at least one plug connector by the retention wire.

37. The preconnectorized outdoor cable of claim 21, one of the half-shells having at least one rib.

38. The preconnectorized outdoor cable of claim 21, the cable further comprising a dry insert being disposed within the cable jacket.

39. The preconnectorized outdoor cable of claim 21, the cable having at least one electrical conductor for transmitting power, the at least one electrical conductor being in electrical communication with an electrical terminal of the plug connector.

40. A preconnectorized outdoor cable comprising:

a cable, the cable having at least one optical waveguide and at least one tensile element, and a cable jacket, wherein the cable jacket generally surrounds the at least one optical waveguide and the at least one tensile element; and

at least one plug connector, the at least one plug connector being attached to a first end of the cable, thereby connectorizing at least one optical waveguide, the at least one plug connector comprising;

a crimp assembly, wherein the crimp assembly includes a crimp housing and a crimp band, wherein the crimp housing comprises two half-shells being held together by the crimp band, the two halt-shells having a longitudinal passageway for passing the at least one optical fiber therethrough, at least one cable clamping portion, and a connector assembly clamping portion, wherein the at least one cable clamping portion secures the at least one tensile element of the cable;

a heat shrink tube for weatherproofing the preconnectorized outdoor cable, the heat shrink tube being disposed over a portion of the at least one plug connector and a portion of the cable jacket; and

a connector assembly, the connector assembly includes a connector body and a ferrule, wherein a portion of the connector assembly is secured in the connector assembly clamping portion of the two half-shells of the crimp housing.

41. The preconnectorized outdoor cable of claim 40, the connector housing clamping portion being configured for securing more than one connector assembly.

42. The preconnectorized outdoor cable of claim 40, the at least one tensile element being a strength component having an anti-buckling strength characteristic.

43. The preconnectorized outdoor cable of claim 40, the at least one tensile element being a strength memver that essentially lacks an anti-buckling strength characteristic.

44. The preconnectorized outdoor cable of claim 40, the longitudinal passageway being a curvilinear longitudinal passageway for routing the at least one optical waveguide.

45. The preconnectorized outdoor cable of claim 40, the at least one plug connector further comprising a shroud, the shroud having a keyed passageway for inhibiting rotation between the shroud and the crimp assembly.

46. The preconnectorized outdoor cable of claim 40, further comprising a coupling nut for removably attaching the at least one plug connector with a complementary mating receptacle.

47. The preconnectorized outdoor cable of claim 40, the at least one plug connector further comprising a shroud for protecting the connector assembly.

48. The preconnectorized outdoor cable of claim 47, the shroud defining a pair of openings on opposite sides of a first end, the opening extending lengthwise from a medial portion of the shroud to the first end of the shroud, wherein the ferrule is accessible within the first end of the shroud.

49. The preconnectorized outdoor cable of claim 47, the shroud having two fingers for mating with a complementary receptacle, wherein the two fingers are disposed about 180 degrees apart and have different cross-sectional shapes for keying the plug connector with the complementary receptacle.

50. The preconnectorized outdoor cable of claim 47, further comprising an O-ring disposed on the shroud for weatherproofing the at least one plug connector.

51. The preconnectorized outdoor cable of claim 40, the at least one plug connector further comprising a shroud having a first end and a second end, wherein the shroud has at least one alignment indicia for indicating a mating orientation.

52. The preconnectorized outdoor cable of claim 40, the at least one plug connector further comprising a shroud having a first end and a second end, the shroud has a plurality of fingers for mating with a complementary receptacle, wherein at least two of the fingers have different cross-sectional shapes for keying the plug connector with the complementary receptacle.

53. The preconnectorized outdoor cable of claim 40, the at least one plug connector having a protective cap and a retention wire, wherein the protective cap is attached to the at least one plug connector by the retention wire.

54. The preconnectorized outdoor cable of claim 40, the at least one cable clamping portion having at least one rib for securing the at least one tensile element.

55. The preconnectorized outdoor cable of claim 40, a plurality of the components of the at least one plug connector being formed from a UV stabilized material.

56. The preconnectorized outdoor cable of claim 40, the cable further comprising a dry insert being disposed within the cable jacket.

57. The preconnectorized outdoor cable of claim 40, the cable having at least one electrical conductor for transmitting power, the at least one electrical conductor being in electrical communication with an electrical terminal of the plug connector.

59. The preconnectorized outdoor cable of claim 40, the crimp assembly further comprising a crimp band for holding the two half-shell together.

58. A preconnectorized outdoor cable comprising:

a cable, the cable having at least one optical waveguide and at least one tensile element, and a cable jacket, wherein the cable jacket generally surrounds the at least one optical waveguide and the at least one tensile element; and

at least one plug connector, the at least one plug connector being attached to a first end of the cable, thereby connectorizing at least one optical waveguide, the at least one plug connector comprising;

a crimp assembly, wherein the crimp assembly includes a crimp housing, wherein the crimp housing comprises two half-shells, the two half-shells having a longitudinal passageway for passing the at least one optical fiber therethrough, at least one cable clamping portion, and a connector assembly clamping portion, wherein the at least one cable clamping portion secures the at least one tensile element; and

a connector assembly, the connector assembly includes a connector body and a ferrule, wherein a portion of the connector assembly is secured in the connector assembly clamping portion of the two half-shells of the crimp housing.