Abstract:
In some embodiments, the present disclosure is directed at an optical fiber connector that occupies a small volume, and can therefore fit into small optical modules. In some embodiments, the optical fiber connector may comprise a removable faceplate. During installation, the faceplate may be removed to allow an optical fiber plug with a flange to be placed within the optical fiber connector. The flange may comprise one or more spring tabs. The faceplate may then be re-attached to the optical fiber connector, wherein at least a portion of the faceplate engages with the flange and secures the optical fiber plug with the optical fiber connector. The one or more spring tabs may also engage with the removable faceplate, thereby holding the optical fiber plug in place so as to ensure proper light transmission from the fiber to an opposing fiber.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Application No. 62/351,386 titled “SPACE SAVING OPTICAL FIBER CONNECTOR” filed on Jun. 17, 2016, the entire contents of which are incorporated herein by reference. 
     
    
     TECHNICAL FIELD 
       [0002]    The present disclosure relates to connectors for coupling optical fibers. 
       BACKGROUND 
       [0003]    Current optical fiber connectors use a metal or plastic one or two piece connector body. One example of such optical fiber connectors are LC duplex connectors. However, with optical module form factors getting smaller, the need for compact fiber connectors is becoming more and more critical. There is therefore a need for compact optical fiber connectors that can fit into smaller optical modules, and that are also easy to install and service. 
       SUMMARY 
       [0004]    According to one aspect, the present disclosure is directed at an optical fiber connector that occupies a small volume, and can therefore fit into small optical modules. In some embodiments, this optical fiber connector can reduce the volume necessary to house the hardware needed to establish the optical connection. 
         [0005]    In some embodiments, the optical fiber connector can connect two or more optical fibers in a single connector assembly, such that signals passing along one or more optical fibers can be transmitted efficiently to one or more other optical fibers. Whereas prior optical fiber connectors required two separate connector ports, the presently disclosed optical fiber connector can eliminate the need for two separate ports, thereby reducing its size. 
         [0006]    In some embodiments, the optical fiber connector can be configured to couple with one or more optical fibers using a standard, off-the-shelf LC connector, according to the IEC 61754-20 standard. The optical fiber connector can also be configured to couple with one or more optical fibers using a non-standard, compact connection that saves space. In some embodiments, the optical fiber connector can couple an optical fiber having an LC connector with an optical fiber having a non-standard, compact connection. In yet other embodiments, the optical fiber connector can couple two or more optical fibers having the non-standard, compact connections described herein with each other. 
         [0007]    In some embodiments, the optical fiber connector may comprise a removable faceplate. During installation, the faceplate may be removed to allow an optical fiber plug with a flange to be placed within the optical fiber connector. The flange may comprise one or more spring tabs. The faceplate may then be re-attached to the optical fiber connector, wherein at least a portion of the faceplate engages with the flange and secures the optical fiber plug with the optical fiber connector. The one or more spring tabs may also engage with the removable faceplate, thereby holding the optical fiber plug in place so as to ensure proper light transmission from the fiber to an opposing fiber. 
         [0008]    According to another aspect, the present disclosure is directed at a compact optical fiber connector, comprising: a connector body comprising a first end configured to couple with a first optical fiber; and a faceplate configured to be coupled to a second end of the connector body opposite the first end, wherein the faceplate defines an opening for a second optical fiber to pass through the faceplate; wherein, when the faceplate is coupled to the second end of the connector body, the faceplate and the second end of the connector body define an interior volume configured to receive a flange that extends radially outward from a longitudinal axis of the second optical fiber, the flange comprising one or more spring tabs configured to push against an interior surface of the faceplate, thereby biasing the flange against an interior surface of the second end of the connector body. 
         [0009]    In some embodiments, the first end of the connector body comprises a standard LC connector port for receiving a standard LC plug attached to the first optical fiber. 
         [0010]    In some embodiments, the compact optical fiber connector further comprises a split sleeve configured to receive and align a first fiber ferrule from the first optical fiber and a second fiber ferrule from the second optical fiber. 
         [0011]    In some embodiments, the flange is shaped in the form of at least one of a disc, a rectangle, a triangle, and a hexagon. 
         [0012]    In some embodiments, the flange has a diameter that is greater than a diameter of the second optical fiber. 
         [0013]    In some embodiments, the faceplate is configured to be detachably coupled to the second end of the connector body using one or more screws. 
         [0014]    In some embodiments, the faceplate is configured to be coupled to the second end of the connector body using at least one of a snap fit, a friction fit, a press fit, epoxy, sonic welding, and heat welding. 
         [0015]    In some embodiments, each spring tab comprises at least one of a compression spring, wavy washer, finger washer, and photo etched spring tab. 
         [0016]    In some embodiments, each spring tab is coupled to the flange using at least one of a press fit, adhesive, and screws. 
         [0017]    In some embodiments, each spring tab is removably coupled to the flange. 
         [0018]    In some embodiments, each spring tab is an integral part of the flange. 
         [0019]    In some embodiments, the faceplate comprises at least one of plastic and metal. 
         [0020]    According to another aspect, the present disclosure is directed at a method of connecting optical fibers, comprising: providing an optical fiber connector comprising: a connector body comprising a first end configured to couple with a first optical fiber; and a faceplate configured to be coupled to a second end of the connector body opposite the first end, wherein: the faceplate defines an opening, and when the faceplate is coupled to the second end of the connector body, the faceplate and the second end of the connector body define an interior volume. The method further comprises providing a first optical fiber; providing a second optical fiber having a flange that extends radially outward from a longitudinal axis of the optical fiber, the flange comprising one or more spring tabs; coupling the first optical fiber with the first end of the connector body; coupling the second optical fiber with the second end of the connector body by positioning the flange of the optical fiber so that it is adjacent to the second end of the connector body; passing the second optical fiber through the opening of the faceplate; and coupling the faceplate to the second end of the connector body such that the flange is received within the interior volume defined by the faceplate and the second end of the connector body, and the one or more spring tabs of the flange push against an interior surface of the faceplate, thereby biasing the flange against an interior surface of the second end of the connector body. 
         [0021]    In some embodiments, the connector body further comprises a split sleeve having a first end and a second end, the first optical fiber includes a first fiber ferrule, and the second optical fiber includes a second fiber ferrule. Coupling the first optical fiber with the first end of the connector body can comprise inserting the first fiber ferrule into the first end of the split sleeve; and coupling the second optical fiber with the second end of the connector body can comprise inserting the second fiber ferrule into the second end of the split sleeve. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0022]      FIG. 1  is a cross-sectional view of a standard LC-LC adapter connector. 
           [0023]      FIG. 2  is a cross-sectional view of a standard LC-LC adapter connector coupled with two optical fibers. 
           [0024]      FIG. 3  is an exterior view of a standard LC-LC adapter connector. 
           [0025]      FIG. 4  depicts a custom optical fiber plug with an integral spring feature, according to some embodiments. 
           [0026]      FIG. 5  depicts a custom connector configured to couple with a custom optical fiber plug, according to some embodiments. 
           [0027]      FIG. 6  is a close-up view of the custom connector, according to some embodiments. 
           [0028]      FIG. 7  depicts a side-by-side comparison of a standard LC-LC adapter connector and a custom optical connector, according to some embodiments. 
       
    
    
     DETAILED DESCRIPTION 
       [0029]      FIG. 1  is a cross-sectional view of a common, off-the-shelf LC-LC adapter connector  100 . Current LC duplex connectors on the market today use a metal or plastic one or two piece connector body  102 . The connector body  100  can comprise two or more opposing LC connector ports  106 ,  108 , each configured to receive a standard LC plug. The connector body  102  can also house a ceramic or metallic split sleeve  104  that connects the LC connector ports  106 ,  108 . The split sleeve  104  is a hollow tube or passage that is used to align fiber ferrule bodies. 
         [0030]      FIG. 2  is a cross-sectional view of the LC adapter connector  100  coupled with two optical fibers  202  and  204 . Each optical fiber  202 ,  204  comprise a standard LC plug  206 ,  208  respectively, and the LC plugs  206 ,  208  are plugged into LC connector ports  106  and  108 , respectively. Each LC plug  206 ,  208  comprises a ferrule  214 ,  216  respectively that are configured to be pushed together in order to transmit optical signals from one optical fiber to another. When the two plugs  206 ,  208  are plugged into LC connector ports  106  and  108  on opposing sides of the adapter  100 , ferrules  214 ,  216  slide into and are aligned by the split sleeve  104 . A spring  210 ,  212  (respectively) in each LC plug  206 ,  208  engages with a hard stop  302 ,  304  (depicted in  FIG. 3 ) disposed within LC connector ports  106  and  108  to hold the LC plug  206 ,  208  in place. The spring  210 ,  212  push the ferrules  214 ,  216  together under compression to allow proper light transmission. 
         [0031]      FIG. 4  depicts a custom optical fiber plug  400  with an integral spring feature, according to some embodiments. The fiber plug  400  may be coupled to one end of an optical fiber  402  and may comprise a ferrule housing  408 . Ferrule housing  408  may be at least partially made from metal, plastic, or any suitably rigid material, and may comprise a ferrule housing flange  410  that extends outward in at least one direction perpendicular to the axis of the fiber  402 . In some embodiments, ferrule housing flange  410  may take the form of an annular, disc-shaped flange that extends radially outward from the axis of the fiber  402 , but other shapes are also possible. For example, ferrule housing flange  410  may be shaped in the form of a rectangle, a triangle, a hexagon, or any other suitable shape. Ferrule housing flange  410  may also comprise one or more spring tabs  406 . Although  FIG. 4  depicts three spring tabs  406 , other embodiments may have fewer or more spring tabs  406 . Each spring tab  406  may comprise a compression spring, wavy washer, finger washer, or a photo etched spring tab. Spring tabs  406  may be attached to flange  410  in various ways, such as a press fit, adhesive, screws, or other methods known in the art. In some embodiments, spring tabs  406  need not be fixedly retained on ferrule housing  406 , but may be removable. In some embodiments, spring tabs  406  may be an integral part of ferrule housing  406 , e.g., the two components may be formed from one monolithic plastic or metal component. Fixedly retaining spring tabs  406  on ferrule housing  406  and/or ferrule housing flange  410  is not necessary, but providing a single fiber connector  400  may aid in assembly. 
         [0032]      FIG. 5  depicts a custom connector  500 , according to some embodiments. Connector  500  can be configured to couple with an optical fiber using a standard LC connector port  508  on one end, and with the custom optical fiber plug  400  depicted in  FIG. 4  on the other end. LC connector port  508  can be configured similarly to one of the standard LC connector ports  106 ,  108  depicted in  FIGS. 1-3 . Connector  500  can also comprise a split sleeve  504  and a faceplate  502 . Split sleeve  504  can be a hollow tube or passage used to align fiber ferrule bodies. Faceplate  502  can comprise a metal, plastic, or other substantially rigid component. Faceplate  502  may be attached to LC connector port  508  using one or more socket head cap screws  506 . In some embodiments, two socket head cap screws  506  can be used. 
         [0033]      FIG. 6  depicts a close-up view of custom connector  500 , according to some embodiments. Fiber ferrule  404  of the custom optical fiber plug  400  can be configured to slide into split sleeve  504 . When another optical fiber is inserted from the opposite end of adapter connector  500  (e.g., through LC connector port  508 ), a fiber ferrule from the opposing optical fiber can also slide into split sleeve  504  and be aligned with fiber ferrule  404 , thereby allowing light to transmit between the two optical fibers. Ferrule housing flange  410  of the custom optical fiber plug  400  can be sandwiched between an interior surface  602  of LC connector port  508  and faceplate  502 , thereby securing fiber plug  400  to the adapter connector  500 . The one or more spring tabs  406  can push against faceplate  502 , thereby compressing ferrule housing flange  410  against interior surface  602  of the LC connector port  508 . This compression also pushes fiber ferrule  404  deeper into split sleeve  504  and against the fiber ferrule from the opposing optical fiber, thereby facilitating proper light transmission. 
         [0034]    During assembly and/or installation, the faceplate  502  may be removed either partially or completely from LC connector port  508  by removing the one or more screws  506 , thus exposing the interior surface  602  of LC connector port  508  and the opening of split sleeve  504 . Then, fiber ferrule  404  may be inserted into split sleeve  504  and ferrule housing flange  410  may be pushed against the interior surface  602  of LC connector port  508 . Next, faceplate  502  may be repositioned over the interior surface  602  of the LC connector port  508 , thereby sandwiching ferrule housing flange  410  between faceplate  502  and LC connector port  508 . The one or more screws  506  may be used to once again secure faceplate  502  to LC connector port  508 . By appropriately tightening screws  506 , faceplate  502  may cause ferrule housing flange  410  to compress against the interior surface of the LC connector port  508 , and ensure an appropriate interface between fiber ferule  404  and the ferrule of an opposing optical fiber. 
         [0035]    Faceplate  502  may comprise materials such as plastic or metal, such as zinc, aluminum, or steel. Faceplate  502  may be formed from one or more injection-molded or machined components. In some embodiments, faceplate  502  may comprise a single monolithic component, or multiple components bonded, attached, or coupled to each other. Faceplate  502  may be attached to LC connector port  508  in various ways. Although  FIGS. 5 and 6  depict faceplate  502  being attached using one or more screws  506 , faceplate  502  may also be attached to LC connector port  508  using a snap fit, a friction fit, or a press fit. Faceplate  502  may also be attached using epoxy, sonic welding, or heat welding. Faceplate  502  may also take different shapes in various embodiments, including but not limited to triangular, circular, and hexagonal, shapes. Faceplate  502  need not take on a plate-like shape, but may also be formed from a component that is deeper than it is wide (e.g., extends further along the axis of fiber  402  than along one or more directions perpendicular to the axis of fiber  402 ). Faceplate  502  may contain an opening for fiber  402  to pass through, and the opening may also assume a variety of shapes, including without limitation, triangular, rectangular, circular, or hexagonal shapes. In some embodiments, having a removable faceplate (such as faceplate  502 ) may allow use of a standalone ferrule fiber assembly, thereby eliminating the need for bulky connector body inside the connector module. For instance, the removable faceplate may eliminate the need to house a full standard LC connector plug inside the connector body. 
         [0036]      FIG. 7  depicts a side-by-side comparison of a fiber-to-fiber coupling facilitated by the standard LC-LC adapter connector  100  vs. the presently disclosed custom optical connector  500 , according to some embodiments. Adapter connector  100  is depicted as coupling fibers  706   a  and  706   b  with fibers  708   a  and  708   b , wherein the optical fibers are inserted into standard LC ports  106  and  108 . Custom optical connector  500  is depicted as coupling fibers  710   a  and  710   b  with fibers  712   a  and  712   b . Fibers  710   a  and  710   b  are coupled to the connector  500  via LC connector port  508 , whereas fibers  712   a  and  712   b  are coupled to the connector  500  using the custom optical fiber plugs  400  depicted in  FIG. 4 . As can be seen, custom optical connector  500  eliminates the need for a second LC port  106 , and can therefore save significant space compared to the standard optical connector  100 . In some embodiments, the length of custom optical connector  500 , as measured from reference plane  706 , can be up to 15 mm, or 0.6 inches, shorter than the length of standard LC connector  100 . This saved space allows more freedom in space constrained design of optical modules. 
         [0037]    While custom optical connector  500  is depicted as having one standard LC port  508  coupled to a single faceplate  502 , other embodiments which dispense with the standard LC port  508  are also possible. For example, an optical connector may be configured to interface with the custom optical fiber plug  400  on both opposing ends of the connector instead of only on one end. The optical connector in such embodiments may comprise a substantially rigid body with a split sleeve disposed within, wherein opposing sides of the body are covered with a faceplate. Both opposing faceplates may be secured to the body with one or more screws. In this way, the optical connector may be configured to receive the custom optical plug  400  on both opposing ends of the connector instead of only at a single end. Receiving the custom optical plug  400  on both opposing ends can enable the optical connector to save even more space in optical module assemblies.