Abstract:
An optical fiber splice case particularly adapted for providing fiber optic links directly to a home, business, et al. is provided wherein at least one enclosure base has at least one cover member selectively sealingly engaged with at least one side of the at least one enclosure base. The at least one enclosure base includes at least one bulkhead having a selective plurality of optical fiber ports therethrough.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     The subject invention is directed to a convertible waterproof and airtight cable splice enclosure assembly. Assemblies of the type under consideration are particularly suited for enclosing and housing fiber optic cables such as loose buffer and unitube type cables and will be described with particular reference thereto. However, the apparatus could equally well be used with other types of cables or wires such as, for example, hybrid cables including copper wire, twisted pair wire or co-axial cables.  
         [0002]     Many different types of fiber optic cable enclosures are known in the prior art. These prior enclosures are satisfactory to a greater or lesser degree but often have-certain defects which make them inconvenient to use or prevent them from being readily adaptable to changing environments and conditions. One example of a optical fiber splice case that presents a significant improvement over the earlier devices found in the prior art is taught in U.S. Pat. No. 6,215,939, the teachings of which are incorporated herein by reference. In addition to providing improvements over the various prior art devices, the subject optical fiber splice case presents further significant new advances over the earlier apparatus as well.  
         [0003]     Service providers (i.e. communication companies) are providing fiber optic links directly to a home, business, apartment, and even the farm. In order for service providers to keep their infrastructure costs low, a terminal enclosure must be provided to allow for ease of initial installation into service, and time savings for adding (linking) individual subscribers. Adding an individual subscriber is commonly referred to as providing a drop. Adding a drop in existing enclosure designs requires splicing on the fiber tray. This is achieved by removing an enclosure from its location and taking it into a temperature controlled environment. Highly skilled personnel then reenter the enclosure and use laser splicing equipment to add the new service (drop). While performing these tasks, any signals passing through the enclosure have the potential to be disturbed. This operation also requires the critical seals of the enclosure to be effected each time new service is added.  
       SUMMARY OF THE INVENTION  
       [0004]     In accordance with one aspect of the invention, there is provided a convertible fiber splice enclosure including at least one enclosure base having a first cover member selectively sealingly engaged with at least one side of the at least one enclosure base. The at least one enclosure base includes a first bulkhead having a first plurality of spaced apart selectively removable webs defining a first set of ports therein for selectively receiving first incoming feed cables therethrough. The enclosure also includes a second bulkhead opposed to the first bulkhead. The second bulkhead has a second plurality of spaced apart selectively removable webs defining a second set of ports therein for selectively receiving second incoming feed cables therethrough.  
         [0005]     In accordance with another aspect of the invention, there is provided an optical fiber splice case including at least one enclosure base having at least one cover member selectively sealingly engaged with at least one side of the at least one enclosure base. The at least one enclosure base includes at least one bulkhead member having a selective number of optical fiber ports therethrough.  
         [0006]     In accordance with still another aspect of the invention, a convertible fiber splice enclosure is provided having a first enclosure base coupled to a second enclosure base. The enclosure further includes a first cover member selectively sealingly engaged with an exterior side of one of the first enclosure base and the second enclosure base. A second cover member is selectively sealingly engaged with an exterior side of another of the first enclosure base and the second enclosure base. At least one of the first and the second cover members includes selectively blocked ports for receiving connector housings therethrough.  
         [0007]     In accordance with yet another aspect of the invention, an optical fiber splice case is provided including at least one enclosure base. The at least one enclosure base further includes at least one cover member having a plurality of fiber adapter ports adapted to sealingly receive fiber adapters. Each of the fiber adapters includes a fiber connector. The fiber connector and the splicing tray include a fiber jumper therebetween.  
         [0008]     In accordance with still a further aspect of the invention, a method is provided for connecting fibers to a plurality of associated end users including the steps of, providing at least one fiber splice case having at least one hingedly retained cover member for accessing a splicing chamber and at least one bulkhead, providing the at least one bulkhead with a plurality of optical fiber ports, pivoting the at least one cover member and installing a feeder cable through the at least one bulkhead in the splicing chamber, feeding a selected number of drop wires through the fiber ports, and replacing the at least one cover member.  
         [0009]     In accordance with yet a further aspect of the invention, a method is provided for connecting an optical fiber to a plurality of end users including the steps of, providing at least one optical fiber enclosure base having at least one hingedly retained cover member for accessing a chamber and at least one end plate, providing the at least one cover member with a plurality of fiber adapters, pivoting the at least one cover member and installing a feeder cable through at least one bulkhead in the chamber, the fiber adapters include connector couplers, connecting the fiber connectors on one side of the at least one cover with the splicing tray via a plurality of fiber jumpers, installing a plurality of dust covers on the other side of the at least one cover to the fiber adapters, replacing the at least one cover member, removing a selected number of dust covers from selected fiber adapters to expose a selected number of connector couplers, and attaching a selected number of drop wires to the selected connector couplers.  
         [0010]     In accordance with still a further aspect to the invention an optical splice case is provided including a convertible fiber splice enclosure having at least one enclosure base and a first cover member selectively sealingly engaged with at least one side of the at least one enclosure base. The enclosure base includes a first bulkhead having a first plurality of spaced apart selectively removable webs defining a first set of ports therein. The enclosure base further includes a second bulkhead opposed to the first bulkhead and having a second plurality of spaced apart selectively removable webs defining a second set of ports therein. A plurality of selectively blocked ports is disposed on the first cover for receiving adapter housings for connecting to outgoing fiber cables.  
         [0011]     Other advantages and benefits of the invention will become apparent to those skilled in the art upon a reading and understanding of the following detailed description. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]     The invention may take physical form in certain parts and arrangement of parts, embodiments of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof, and wherein:  
         [0013]      FIG. 1  shows a perspective view of a first embodiment of a housing assembly intended for use with fiber optic cable;  
         [0014]      FIG. 2  is a perspective view of the housing assembly of  FIG. 1  with a cover in the open position;  
         [0015]      FIG. 3   a  is a perspective view of the cover member;  
         [0016]      FIG. 3   b  is an enlarged elevational view of the retention bolts securing a cover to the base in the retained position;  
         [0017]      FIG. 3   c  is an enlarged elevational view of the retention bolts securing a cover to the base in the secured position;  
         [0018]      FIG. 4  is a perspective view of a housing assembly according to a second version of the first embodiment of the present invention;  
         [0019]      FIG. 5  is an enlarged perspective view of the restraint bracket;  
         [0020]      FIG. 6  is an enlarged perspective view of the restraint bracket;  
         [0021]      FIG. 7  is an enlarged top perspective view illustrating the end plate;  
         [0022]      FIG. 8  is an enlarged bottom perspective view illustrating the end plate;  
         [0023]      FIG. 9  is an enlarged front perspective view illustrating the bulkhead of an enclosure base;  
         [0024]      FIG. 10  is a bottom perspective view of the cover member according to the first embodiment of the housing assembly;  
         [0025]      FIG. 11  shows a perspective view of a second embodiment of a housing assembly intended for use with fiber optic cable;  
         [0026]      FIG. 12  is an exploded view of the subject convertible housing assembly illustrating interchangeable cover members;  
         [0027]      FIG. 13  shows a perspective view of the second embodiment of a housing assembly intended for use with fiber optic cable;  
         [0028]      FIG. 14  is an enlarged perspective partial view of the housing assembly of  FIG. 13 ;  
         [0029]      FIG. 15  shows a cover member in the opened position according to the second embodiment;  
         [0030]      FIG. 16  is an enlarged inside perspective view of a plurality of connector housings according to the second embodiment;  
         [0031]      FIG. 17  is a perspective view of the cover member of the housing assembly of  FIG. 15  illustrating a pair of hinge legs and holes adapted to receive the enclosure base;  
         [0032]      FIG. 18  shows an exploded assembly of two enclosure bases in a relative position just prior to joining according to a third embodiment of the present invention;  
         [0033]      FIG. 19  is a perspective view of a first version of an assembly housing according to the third embodiment of the invention;  
         [0034]      FIG. 20  is a perspective view of a second version of the assembly housing according to the third embodiment;  
         [0035]      FIG. 21  is a perspective view of a third version of the assembly housing according to the third embodiment;  
         [0036]      FIG. 22  is a top perspective view of the assembly housing of  FIG. 21 ; and,  
         [0037]      FIG. 23  is an enlarged perspective view of a shroud adapted to be used with non-hardened connectors. 
     
    
     DETAILED DESCRIPTION  
       [0038]     Referring now to the drawings wherein the showings are for the purposes of illustrating embodiments of the invention only and not for purposes of limiting same, the overall construction of the subject fiber (i.e. optical) splice case, housing or enclosure assembly  10 , according to a first embodiment, can best be understood by reference to  FIGS. 1-10 . As illustrated therein, the splice case assembly housing  10  comprises an enclosure base or splice case  12 , an enclosure cover member  14 , and an end plate  16 . The assembly housing  10  encloses a splice chamber or splice tray support area  20  and a drop chamber or a fiber jumper storage compartment  23  as shown. The housing assembly  10  formed by the cover member  14 , enclosure base  12 , and the end plate  16  are joined together in a sealed clamping relationship to define a somewhat flat truncated oval-shaped splice case volume area therein.  
         [0039]     Although the housing body components and the end plates could be formed from a variety of different materials using different manufacturing techniques, in the subject embodiment, they are preferably injection molded from a suitable plastic, containing fibers for reinforcement. For example, fiber glass filled and reinforced polypropylene.  
         [0040]     The enclosure base  12  includes a pair of bulkheads  26 ,  28  at opposing ends. The bulkheads  26 ,  28  include breakout webs  30  which can be selectively punched out from the bulkhead in order to create an opening or port  32  therethrough. The housing assembly  10  can be configured for butt or in-line configurations. For butt configurations, the closure cover  14  can be sealed against the enclosure base  12  without having an end plate  16  installed. For in-line configurations, the enclosure base  12  is adapted to receive end plates  16  at opposing ends which can be sealingly engaged with the cover member  14 . The housing assembly  10 , specifically the bulkheads  26 ,  28  of the enclosure base  12  are adapted to selectively receive a grommet  40  whereby incoming feed or feeder cables  42  and outgoing drop wires  44  can extend selectively through the same port or opening  32  through the bulkheads  26 , 28 , or can extend through another opening through the bulkhead ( FIG. 4 ).  
         [0041]     Referring now to  FIG. 2 , the enclosure base  12  can include a splice tray  50  therein. The cover member  14  can be pivoted relative to the enclosure base  12  whereby access to the splice tray  50  is facilitated. It is to be appreciated that the cover member  14  can be hinged and pivoted either to the left or to the right. Referring to  FIG. 3 , the cover member  14  can be secured to the enclosure base  12  with self-retaining mounting bolts  54 . Retaining sleeves  56  allow the bolts  54  to be retained in bolt mounts  58  along an outer edge  60  of the cover  14  while moving in a position to enable the cover  14  to pivot about the enclosure  12 . In  FIG. 3 , the cover member  14  is shown including bolts  54  for engaging with the enclosure base  12 . The cover member  14  can also include a pair of hinge legs  62  (i.e. a pair on each side) which allow for the cover member  14  to remain attached to the enclosure base  12  after the mounting bolts  54  are disengaged from the enclosure base  12 . It is to be appreciated that each pair of hinge legs  62  enable cover  14  to selectively pivot to one side or the other when bolts  54  are disengaged from base  12 . Hinge legs  62  allow cover  14  to remain attached to base  12  after bolts  54  are disengaged from base  12 .  
         [0042]     Referring now to  FIGS. 5 and 6 , the housing assembly  10  can include a pair of restraint brackets  70  for anchoring the feed cables  42 . The restraint brackets  70  can include a self-tapping screw  72  for mounting to the enclosure base  12 . The restraint brackets  70  also include support ribs  74  that can engage splice trays  50  to increase stability.  
         [0043]     Referring again to  FIGS. 2 and 4 , the selective openings  32  through the bulkheads  26 ,  28  are adapted to receive grommets  40 . The grommets  40  can be used for sealing incoming cables  42  or gel sealant can be wrapped around the incoming cables  42 . The grommets  40  can include a plurality of openings therethrough capable of accommodating a selected combination of incoming feed cables  42  and outgoing drop wires  44 . As shown in  FIG. 7 , the end plate  16  can be mounted with mounting bolts  76  to the enclosure base  12 . The end plates  16  include sealing beads  78  to imbed into a gasket on the interior of the cover surface thereby sealingly engaging the grommets  40 . The enclosure base  12  also can include a tray support or storage bracket  80 . The storage bracket includes a retention post. The storage bracket  80  can pivot around the retention post  82  to allow fiber to be captured below the storage bracket  80 .  
         [0044]     Referring now to  FIG. 4 , an in-line configuration of the housing assembly  10  is shown. The in-line configuration includes incoming feed cables  42  and outgoing fiber drops  44  passing through both bulkheads  26 ,  28  of the enclosure base  12 . It is to be appreciated that end plates  16 , best shown in  FIGS. 7 and 8 , can be installed at each end of the enclosure base  12  over the respective bulkheads  26 ,  28 .  
         [0045]     Referring to  FIG. 9 , bulkhead  26  is there displayed. A perimeter rib surface  90  seals against the cover to eliminate the end plate in a butt application. If access is desired through one or both ends of the enclosure base  12 , break out walls or webs  30  are selectively removed from the bulkhead  26 . A V-groove  94  around the perimeter of the break out web  30  creates a thin section conducive for breaking out the wall of the web  30 . Ribbed walls  96  around the break out web  30  reinforce the structure so that it does not break when the wall  30  is removed. It is to be appreciated that break out webs  30  can be left in place until needed.  
         [0046]     The enclosure base  12  includes fastener holes  100  around a perimeter  102  for the cover member  14  attachment. The perimeter  102  also includes fastener holes  103  for stacking a pair of enclosure bases together, to be described hereinafter. The enclosure base  12  also includes flanges proximal to opposing bulkheads  26 ,  28  for receiving the end plates  16 . The installation of the end plates  16  provides the continuation of a perimeter sealing ring when break out walls or webs  30  are removed. The enclosure base  12  also includes the perimeter sealing ring or rib  90 .which compresses against a cover member gasket  106  which can be mounted on the inside of the cover member  14  to form a seal therearound. Referring to  FIG. 10 , the cover member  14  can include the cover member gasket  106  on the inside of the cover member  14 .  
         [0047]     The enclosure base  12  can also provide for a base window or opening which can be either molded solid or selectively opened. In the opened arrangement, the base window can provide access between adjacent enclosure bases in an enclosure stack assembly, to be described hereinafter.  
         [0048]     Referring again to  FIGS. 2, 5 , and  6 , it is to be appreciated that the restraint brackets  70  include a slotted hole  120  for attachment to the enclosure base  12 . The restraint brackets  70  also include bracket legs  122  which can be bent outward to compensate for cable diameter ranges and can retain feeder cables  42  thereon. The restraint brackets  70  also include a plurality of slots  124  for retaining a strap that secures fiber splice trays  50  in the enclosure base  12 . The restraint brackets  70  provide support rib or protrusion member  74  that engages a corresponding groove  134  on splice trays  50  thereby increasing their stability within the-housing assembly  10 . The restraint brackets  70  include a pair of caps  136  for retaining a strength member of the feed cables  42 .  
         [0049]     Referring now to  FIGS. 11-17 , a second embodiment of a housing assembly is illustrated. As illustrated therein, a splice case housing assembly  210  adapted for hardened connectors can be configured for butt or in-line configurations. For butt configurations, a closure cover or cover member  214  is arranged to seal against the enclosure base  12  without having an end plate  16  installed. The housing assembly  210  can be reconfigured into an in-line enclosure by adding an end plate  16  to an opposing end of the enclosure base  12  and breaking out a selected number of webs  30  at the respective bulkhead. As will be described in more detail hereinafter, after initial installation of the feed fibers  42  and subsequent splicing to a back side of a hardened connector, the housing assembly  210  does not need to be reopened to provide service to a customer. This feature allows a lesser-trained installer to make the connection to the customer, thus reducing the future installation costs of the service provider.  
         [0050]     The cover member  214  can include selectively blocked ports or molded over holes  220  adapted to receive connector (adapter) housings or fiber adapters  222 . Incoming feed cables  42  can pass through the bulkhead of the enclosure base  12 . The connector housings  222  can be covered with protective caps or dust covers  224  until a connection is desired. The protective caps  224  can be factory or field installed. As shown in  FIGS. 13 and 14 , the connector housings  222  include couplers  223  which are adapted to matingly receive hardened connectors  226 ,  227 . The hardened connectors  227  include a fiber drop wire  250  extending therefrom. Fiber jumpers  240 , including connectors  226 , can be connected to the back side of the connector housings  222  and routed onto the splice tray for connection to the feed cables  42 . As shown in  FIGS. 15 and 16 , a threaded nut  242  can be provided for securing the connector housing  222  to the cover member  214 . It is to be appreciated that the fiber jumpers  240 , along with the connectors  226  mounted in connector couplers or feed thru adapter modules  223 , allow a signal to flow from the fiber jumper  240  out to the external fiber drop cable  250 .  
         [0051]     As shown in  FIG. 17 , the cover member  214  to be used with hardened connectors  226 ,  227  can include a plurality of holes  220  which can be initially molded over, thereby eliminating the need to supply a connector housing  222  therein. As connectors are needed, the molded over holes  220  can be opened and a connector housing  222  received therein. The holes  220  include flat sides  252  which prevent rotation of the connector housing  222  during installation. The holes  220  can also include a recessed ring  254  for retention of an o-ring (not shown) thereby creating a seal between the connector housing  222  and the cover member  214 . The cover member  214  includes a pair of hinge legs  260  at opposing ends of one side, or both sides (not shown), and a plurality of mounting bolts  54  for engaging with the enclosure base  12 . The cover member  214  can also include a cover gasket (not shown) mounted to the inside surface of the cover member.  
         [0052]     In order to connect the housing assembly  210  to an individual end user, an operator removes one or more of the dust covers  224  from the fiber adapters  222  to expose the fiber connector coupler  223 . The operator attaches the drop wire  250  including the hardened connector  227  thereon which has been prefitted with an internally threaded cap  272 . It is to be appreciated that the steps to connect an individual end user takes only a matter of minutes and does not disturb the integrity of the enclosure seals. The ease of connection allows an operator with less technical capability to add service (drops) to a plurality of customers in an extremely efficient manner without affecting signals passing through to other customers.  
         [0053]     Referring now to  FIGS. 18-23 , a third embodiment of a splice case housing assembly  300  is illustrated. As illustrated therein, a stacked design is provided which allows for two independent chambers to keep the feed side of the closure protected and/or secured from the installer adding drop fibers to the splice case housing assembly. The stacked design also provides for a secondary chamber which increases the drop capacity of the housing assembly. It is to be appreciated that either cover member  14 ,  214 , described in the first and second embodiments, can be used on either side of the housing assembly  300  which allows the unit to be configured for non-hardened or hardened connectors. Each cover member  14 ,  214  can have distinctive securing means thereby restricting access to one side of the housing assembly  300  if desired.  
         [0054]     Referring now to  FIG. 18 , a pair of enclosure bases  12  can be assembled together to form a housing assembly with two independent chambers. A base window  304  can be removed to allow for passing of fibers between the opposing chambers. Window gasket  306  can be captured between the enclosure bases  12  to seal the base window  304  openings. Fasteners  307 ,  308  can be used to secure the enclosure bases  12  together.  
         [0055]     Referring now to  FIG. 19 , a first version of the housing assembly  300  according to the third embodiment is shown. The housing assembly  300  includes independent chambers whereby one chamber accommodates incoming feed cables and a standard cover member  14 . The other chamber comprises a drop chamber whereby a cover  214  including hardened connectors is provided.  
         [0056]      FIG. 20  illustrates a second version whereby the housing assembly  301  includes a pair of cover members  214  in which both plates accommodate hardened connectors. By providing hardened connectors on both cover members  214 , an increase in drop capacity is provided. The enclosure bases  12  can be elongate defining a longitudinal axis  309  therethrough. A first set of bulkhead ports can be adapted to receive an associated first cable into the enclosure along a first insertion axis  310 . A second set of bulkhead ports can be adapted to receive an associated second cable into the enclosure along a second insertion axis. The first insertion axis and the second insertion axis can be generally parallel to and offset from the longitudinal axis  309  defined by the enclosure base  12 .  
         [0057]     As best shown in  FIG. 20 , it is to be appreciated that each cover  214  can be adapted to receive cables into the enclosure along third and fourth insertion axes  312 ,  313 , respectively. The third insertion axis forms an angle  314  less than 90 degrees relative to the longitudinal axis  309  defined by its associated enclosure base. As shown, the angle is about 45 degrees. Similarly, the fourth insertion axis forms an angle  315  less than 90 degrees relative to the longitudinal axis  309  defined by its associated enclosure base. Also as shown, the angle is about 45 degrees. It is to be appreciated that the third insertion axis  312  is generally parallel to the fourth insertion axis  313 . The adapter housings can generally be arranged in rows and/or columns relative to the longitudinal axis  309 .  
         [0058]     Referring now to  FIGS. 21-23 , a splice case housing assembly  302  including a pair of enclosure bases  12  is illustrated and is adapted for non-hardened connectors. This embodiment allows for standard drop wire to be used for the outgoing drops. Also, this embodiment allows for a higher quantity of drop wire to exit the drop chamber versus the hardened connector version. In particular, the housing assembly  302  includes standard cover members  14  mounted on opposing sides of the pair of enclosure bases. Two independent chambers are formed, namely a drop chamber and a feed chamber. Incoming feed cables can be supplied through one of the enclosure bases. The incoming feed fibers can be spliced to fiber jumpers on the splice tray (not illustrated). Once spliced, the fiber jumpers can be routed through the base window into the drop chamber and connected to the back of the bulkhead plate. A shroud  320 , including a bulkhead plate  322 , is provided, thereby creating an area to splice fiber jumpers  323  to the outgoing fiber drops. The outgoing fiber drops are routed through apertures in the grommet and extend through the bulkhead of one of the enclosure bases  12 .  
         [0059]     As shown in  FIG. 22 , the shroud  320  covers the base window on the drop chamber side, thereby preventing tampering with a feed signal connection.  
         [0060]     Obviously, modifications and alterations will occur to others upon a reading and understanding of this specification. It is intended that the invention be construed as including all such modifications and alterations as fall within the scope of the appended claims or the equivalents thereof.