Abstract:
A system ( 10 ) and method that facilitates the delivery of power and fiber communications together is provided. The system and method enables quick and easy connection of a hybrid cable ( 12 ) to telecommunication equipment. The system provides a sealed robust connection for both conductors ( 78, 80 ) and fibers ( 50 ) at a single location ( 56 ). It can be used to avoid the need for local powering of fiber based communication devices and networks.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Patent Application Ser. No. 62/066,230, filed on Oct. 20, 2014, the disclosure of which is incorporated herein by reference in its entirety. 
     
    
     BACKGROUND 
       [0002]    Fiber optic based telecommunication services are being extended to an increasing number of businesses and homes. Many of these extensions of service within neighborhoods, industrial parks and business developments utilize optical fiber distribution cables laid within buried conduit. Such optical fiber distribution cables typically extend from a larger fiber distribution terminal or pedestal to a smaller fiber access terminal directly adjacent the business or home to which service may be provided. From the fiber access terminal to the home or business, a fiber drop cable may connect to the home or business. 
         [0003]    When fiber optic cables are extended from a fiber distribution terminal to a fiber access terminal, a variety of techniques are available for sealing and anchoring the cables relative to the fiber access terminal. It is generally desirable to provide sealing and anchoring configurations that are secure, reliable, and cost effective. In certain applications it is desirable to provide both fibers for data transmission along with copper for power transmission. The integration of power and fiber communication into one system can greatly speed up installation of network devices. For example, the integration fiber and power (e.g., copper) can facilitate the installation of a variety of devices requiring optical communications and power such as: small cells, ONT&#39;s, FTTX, digital signage, industrial communications, POLAN, PoE or PoE+ extension, Wifi access points. 
       SUMMARY 
       [0004]    The present disclosure provides a system and method that facilitates the delivery of power and fiber communications to telecommunication equipment. The system and method enables quick and easy connection of a hybrid cable to telecommunication equipment. The system provides a sealed robust connection for both conductors and fibers at a single location. The system and method can be used to avoid the need for local powering of fiber based communication devices and networks. In some applications, the system and method are employed to extend the distance that powered devices can be installed from the power source in Power over Ethernet (PoE+) installations. The powered device could be, for example, an IP camera, a wireless access point, or other building automation device located in an area where an electrical outlet is not readily available. 
         [0005]    One embodiment of a method of connecting a jacketed hybrid electrical optical cable to telecommunication equipment includes the following steps: exposing end portions of a pair of conductors, one or more of optical fibers and a plurality of strength members from a distal end portion of a jacketed hybrid electrical optical cable; connecting a plug body to a closure such that a first end portion of the plug body is external to the closure and a second end portion of the plug body is internal to the closure; extending the distal end portion of the jacketed hybrid electrical optical cable through a first end portion of the plug body; securing the distal end portion of the jacketed hybrid electrical optical cable to the plug body; electrically connecting the pair of conductors of the jacketed hybrid electrical optical cable to a pair of metal tabs mounted in a potting housing of a plug body, the potting housing located at the second end portion of the plug body; extending a pair of secondary conductors through a cover assembly and engaging end portion of the pair of secondary conductors with conductive contacts located in the potting housing; guiding the plurality of optical fibers out of the cover assembly; positioning the cover assembly over the potting housing; and filling the potting housing with an epoxy. 
         [0006]    In one embodiment a sealing and retention plug for a jacketed hybrid electrical optical cable includes the following features: a plug assembly including a plug body, the plug body including: a first end portion including an opening at a distal end configured to receive a jacketed hybrid electrical optical cable, the first end portion configured to slide over a distal end portion of a jacketed hybrid electrical optical cable; a second end portion including: a potting housing, the potting housing including a bottom wall and two opposed side walls; a cover assembly that is configured to slide over the potting housing, the cover assembly including a top wall, a bottom wall, an open first end and a second end wall, the second end wall including a pair of conductor apertures for receiving conductors and a fiber aperture for receiving one or more of optical fibers; and a closure interface assembly located between the first end portion and second end portion, the closure interface assembly includes a flange configured to engage the exterior of a closure, the closure interface assembly further comprises a treaded barrel adjacent the flange and a nut that is configured to engage the threaded barrel and tightened to drive the flange against the closure and compress an O-ring positioned around the threaded barrel thereby creating a seal between the closure and the plug. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0007]      FIG. 1  is an isometric view of a hybrid cable connected to a plug in accordance with the principles of the present disclosure; 
           [0008]      FIG. 2  is an isometric view of  FIG. 1  showing the internal connections between the plug and hybrid cable of  FIG. 1 ; 
           [0009]      FIG. 3  is an isometric view of a hybrid cable before it is engaged with the plug of  FIG. 1 ; 
           [0010]      FIG. 4  is an isometric view of a hybrid cable after it has been inserted into a first end of the plug of  FIG. 1  and before potting; 
           [0011]      FIG. 5  is an isometric view of a hybrid cable connected to the plug of  FIG. 1  and the plug of  FIG. 1  connected to a closure; 
           [0012]      FIG. 6  is an enlarged view of the second end of the plug of  FIG. 1  with optical fibers and conductors connected thereto; 
           [0013]      FIG. 7  is an assembly view of the second end of the plug of  FIG. 1 ; 
           [0014]      FIG. 8  is an enlarged view of a conductive bracket of the plug of  FIG. 1 ; and 
           [0015]      FIG. 9  is an isometric view of the plug of  FIG. 1  with the cover removed and heat shrunk to the hybrid cable. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    Referring to  FIGS. 1-9 , an embodiment of a sealing and retention plug  10  for a jacketed hybrid electrical optical cable  12  in accordance with the principles of the present disclosure is described in further detail. In the depicted embodiment, the plug assembly  10  includes a plug body  14 . The plug body  14  includes a first end portion  16  and a second end portion  22 . The first end portion  16  of the plug body  10  includes an opening at its distal end  18 . In the depicted embodiment, the opening at the distal end  18  is configured to receive a distal end portion  20  of a jacketed hybrid electrical optical cable  12 . In the depicted embodiment the first end portion  16  of the plug body  10  is configured to slide over a distal end portion  20  of a jacketed hybrid electrical optical cable  12 . The cross-sectional size and shape of the first end portion  16  is configured to match the cross-sectional size and shape of the jacketed hybrid electrical cable  12  so that the distal end portion  20  of jacketed hybrid cable  12  can be hand fit into the first end portion  16  of the plug body  10 . It should be appreciated that many other alternative configurations are possible. In alternative embodiments, the first end portion could have a different cross-sectional shape and size than the cross-sectional size and shape of the jacketed hybrid electrical optical cable  12 . In alternative embodiments, the distal end portion  20  of the jacketed hybrid electrical optical cable  12  may not be received within the first end portion  16  of the plug body  10 . 
         [0017]    In the depicted embodiment, the second end portion  22  of the plug body  10  includes a potting housing  24 . In the depicted embodiment, the potting housing  24  includes a bottom wall  28  and two opposed sidewalls  30 ,  32 . In the depicted embodiment, the second end portion  22  also includes a cover assembly  34 . The cover assembly  34  in the depicted embodiment is configured to slide over the potting housing  24 . The cover assembly  34  includes a top wall  36  a bottom wall  38 , and an open first end  40 . The open first end  40  is configured to receive the potting housing  24  as the cover assembly  34  is slid over the potting housing  24 . In the depicted embodiment, a second end wall  42  is located opposite the open first end  40 . The second wall  42  includes a pair of conductor apertures  44 ,  46  for receiving conductors and a fiber aperture  48  for receiving one or more of optical fibers  50 . It should be appreciated that many other alternative configurations are possible. In alternative embodiments, the potting housing  24  and cover assembly  34  could be different from what is depicted in the FIGS. For example, in an alternative embodiment, the potting housing may not have side walls. In alternative embodiments, the cover assembly may be a lid or cap that snaps over the potting housing as opposed to a structure that slides over and receives the potting housing as shown in the depicted embodiment. 
         [0018]    In the depicted embodiment, a closure interface assembly  52  located between the first end portion  16  and second end portion  22  of the plug body  10 . In the depicted embodiment, the closure interface assembly  52  includes a flange  54  configured to engage and abut the exterior of a closure  56 . In the depicted embodiment, the flange  54  prevents the plug body from further extending into the closure as it is larger than the aperture in the closure that is configured to receive the plug body  10 . In the depicted embodiment, the closure interface assembly  52  further comprises a threaded barrel  58  located adjacent the flange  54 . A nut  60  is engaged with the threaded barrel  58  and arranged and configured to be tightened against an interior surface of the closure  56  thereby driving the flange  54  against the closure  56  and securing the plug body  10  onto the closure. In the depicted embodiment the closure interface assembly provides a sealed watertight connection between the plug body  10  and the closure  56 . In the depicted embodiment an O-ring  92  is located around the threaded barrel  58 . When the nut  60  is tightened the O-ring  92  seals the plug body  10  to the wall of the closure  56  to limit moisture intrusion into the closure. It should be appreciated that many other alternative configurations of the closure interface assembly are possible. 
         [0019]    In the depicted embodiment, the cover assembly  34  is constructed of a translucent material. In the depicted embodiment, top wall  36  and bottom wall  38  of the cover assembly ( 34 ) are structurally the same and are both translucent. The cover assembly  34  is configured such that it can be slid over the potting housing  24  with either the bottom wall  28  of the potting housing  24  being adjacent to either the top wall  36  of the cover assembly  34  or, alternatively, the bottom wall  38  of the cover assembly  34  being adjacent the bottom wall  28  of the potting housing  24 . This symmetric configuration of the cover assembly  34  simplifies the assembly. Regardless of the orientation of the cover assembly, once positioned over the potting housing  24 , the components within the potting housing  24  are viewable. This allows for a quick and easy visual inspection of the fiber and electrical connections. It should be appreciated that many other alternative configurations are possible. For example, in alternative embodiments, the cover assembly may not slide over the potting housing and the cover assembly may not be translucent. 
         [0020]    In the depicted embodiment, both the top wall  36  and bottom wall  38  of the cover assembly  34  include a port  62  through which epoxy, glue or any other potting agent can be injected into the potting housing  24 . In the depicted embodiment, the fiber aperture  48  is located between the pair of conductor apertures  44 ,  46 . In the depicted embodiment, the relative positions of the pair of conductors and optical fibers are also such that the optical fibers are located between the pair of conductors. As discussed above, it should be appreciated that many other alternative configurations of the cover assembly are possible. 
         [0021]    In the depicted embodiment, the potting housing  24  includes an anchor  64  for securing tension members that extend from the jacketed hybrid electrical optical cable  12 . Often aramid fibers are located among the plurality of optical fibers  50  to provide support to the cable and enable it to withstand tension forces without causing damage to the plurality of optical fibers  50  or the conductors in the cable. The aramid fibers can be gathered together and forced into a V-shaped opening at a distal periphery edge of the bottom wall  28  of the potting housing. The tension members can be jammed and hence locked into place in the V-shaped opening. The fibers can also be folded back along the outside surface of the bottom wall  28  of the potting housing  24 . Once the cover assembly  34  is positioned over the potting housing the aramid fibers are sandwiched between bottom wall  28  of the potting housing  24  and the cover assembly  34 . Filling the potting housing with epoxy further secures the aramid fibers in place and allows them to continue to protect the plurality of optical fibers  50  and the conductors from damage due to tension on the hybrid cable  12 . As discussed above, it should be appreciated that many other alternative configurations of the potting housing are possible including embodiments that have no aramid fibers (strength members) anchors and embodiments that have different anchoring configurations. 
         [0022]    In the depicted embodiment, the potting housing includes a pair of conductive brackets  66 ,  68 . In the depicted embodiment, a body portion of each of the conductive brackets  66 ,  68  is recessed into the two opposed side walls  30 ,  32  of the potting housing  24 . Each of the conductive brackets  66 ,  68  includes a first tabbed end  70 ,  72  and a second tabbed end  74 ,  76 . In the depicted embodiment, both the first tabbed ends  70 ,  72  and the second tabbed ends  74 ,  76  extend through the two opposed side walls  30 ,  32  of the potting housing ( 24 ). The first tabbed ends  70 ,  72  are each configured to receive and secure an end portion of conductors  78 ,  80  that extend from the jacketed hybrid electrical optical cable  12 . In the depicted embodiment, the first tabbed end is configured such that the end of the conductors of the jacketed hybrid cable  12  can be extended through an aperture  88  in the first tabbed ends  70 ,  72 . The aperture includes at least one locking mechanism that allows the conductor to extend into the aperture and provides mechanical resistance against the conductor from being pulled backwards out of the first tabbed ends  70 ,  72 . The second tabbed ends  74 ,  76  are each configured to receive and secure an end portion of a conductor  82 ,  84  that extends out of the second end wall  42  of the cover assembly  34  towards whatever device is connected thereto. In the depicted embodiment, the second tabbed ends include a fork shaped portion that enables side engagement and securing of a conductor, which would extend through the conductor aperture in the second end wall of the cover assembly. As discussed above, it should be appreciated that many other alternative configurations of the potting housing are possible. Some alternative embodiments have no brackets and others have brackets of different constructions. 
         [0023]    A method of connecting a jacketed hybrid electrical optical cable  12  to telecommunication equipment is also provided. In the depicted embodiment, the method comprises a number of steps in no specific order. It should be appreciated that some embodiments of the method include fewer steps than identified below, whereas other embodiments of the method include more steps. Some steps of the method according to the principles of the present disclosure are identified and described in further detail below. 
         [0024]    In the depicted embodiment, the method can include the steps of exposing end portions of a pair of conductors  78 ,  80  of a hybrid cable  12 , one or more of optical fibers  50  and a plurality of strength members  94  from a distal end portion of a jacketed hybrid electrical optical cable  12 . The step of exposing the conductors and optical fibers could be accomplished in the field with hand tools or at the factory. 
         [0025]    In the depicted embodiment, the method can also include the step of connecting a plug body  10  to a closure  56  such that a first end portion  16  of the plug body is external to the closure, and a second end portion  22  of the plug body is internal to the closure  56 . The step of connecting a plug body  10  to a closure  56  can include the step of extending the second end portion  22  of the plug body  10  into an aperture of the closure  56  until a flange  54  of the plug body engages and abuts an exterior surface of the closure  56 . The step of connecting can further include the step of threading a nut  60  onto a threaded barrel portion of the second end of the plug body  10  until a sealing O-ring  92  is compressed against an inside surface of the closure and the flange is driven against the exterior of the closure. 
         [0026]    In the depicted embodiment, the method can also include the steps of extending the distal end portion of the jacketed hybrid electrical optical cable  12  through first end portion  16  of the plug body  10  as well as the step of securing the distal end portion of the jacketed hybrid electrical optical cable  12  to the plug body  10 . In the depicted embodiment, the step of securing the distal end portion of the jacketed hybrid electrical optical cable  12  to the plug body includes applying a heat shrinking sleeve  90  to the jacketed hybrid electrical optical cable  12  to secure the first end portion  16  of a plug body  10 . It should be appreciated than many alternative or auxiliary securing steps are possible other than heat shrinking 
         [0027]    In the depicted embodiment, the method can include the steps of electrically connecting the pair of conductors  78 ,  80  of the jacketed hybrid electrical optical cable  12  to a pair of metal tabs  70 ,  72  mounted in a potting housing  24  of a plug body  10 , the potting housing  24  located at the second end portion  22  of the plug body  10 . The step of electrically connecting the pair of conductors  78 ,  80  to a pair of metal tabs  70 ,  72  mounted to the plug body  10  can include the step of inserting ends of the conductors  78 ,  80  through apertures in the tabs  70 ,  72  that are configured to receive and mechanically secure ends of the pair of conductors  78 ,  80 . It should be appreciated than there exist alternative ways to make electrical connection with the conductors of the hybrid cable other than connecting them to metal tabs as described above. 
         [0028]    In the depicted embodiment, the method can include the steps of extending a pair of secondary conductors  82 ,  84  through a cover assembly  34  and engaging end portions of the pair of secondary conductors  82 ,  84  with conductive contacts  74 ,  76  located in the potting housing  24 . The step of engaging end portions of the pair of secondary conductors  82 ,  84  with conductive contacts  78 ,  80  located in the potting housing  24  can include engaging exposed end portions of the secondary conductors  82 ,  84  with conductive forked shaped conductive tabs  74 ,  76 . It should be appreciated than there exist alternative ways to make electrical connection with the conductors that extend out of the potting housing other than connecting them to metal tabs as described above. 
         [0029]    In the depicted embodiment, the method can include the steps of guiding the plurality of optical fibers  50  out of the cover assembly  34 . The step of guiding the plurality of optical fibers  50  out of the cover assembly  34  can include sliding a protective over-tubing  86  over the plurality of optical fibers  50  and directing the protective over-tubing through an aperture  48  in the cover assembly  34 . It should be appreciated that many other alternative ways to guide the optical fibers from the hybrid cable out of the potting are possible. 
         [0030]    In the depicted embodiment, the method can include the steps of positioning the cover assembly  34  over the potting housing  24 . In the depicted embodiment, the step of positioning the cover assembly  34  over the potting housing  24  can include sliding the cover assembly  34  over the potting housing  24 , thereby defining an enclosed potting volume configured to receive and retain epoxy. In the depicted embodiment, the method also includes the step of filling the potting housing  24  with an epoxy. It should be appreciated that many other alternative ways exist to define an enclosed potting volume other than sliding a cover assembly over a potting housing. 
         [0031]    In the depicted embodiment, the method can include the steps of curing the epoxy and visually inspecting electrical connections in the potting housing  24  by viewing the connections through the cover assembly  34 . In alternative embodiments either the cover or epoxy or both could be opaque and many not allow for visual inspection of the potted electrical connections. 
         [0032]    In the depicted embodiment, the method can include the steps of anchoring the plurality of tension members of the jacketed hybrid electrical optical cable  12  to the plug body  10 . The step of anchoring tension members of the jacketed hybrid electrical optical cable  12  to the plug body  10  can include collecting together and folding the tension member over a portion of the plug body  10 . It should be appreciated that many alternative ways to manage the strength members  94  (e.g., aramid fibers) are possible. 
         [0033]    The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. 
       PARTS LISTING 
       [0000]    
       
         ( 10 ) sealing and retention plug; plug; plug assembly 
         ( 12 ) jacketed hybrid electrical optical cable 
         ( 14 ) plug body 
         ( 16 ) first end portion of the plug body 
         ( 18 ) distal end of the first end portion of the plug body 
         ( 20 ) distal end portion of the jacketed hybrid electrical optical cable 
         ( 22 ) second end portion of the plug body 
         ( 24 ) potting housing 
         ( 28 ) bottom wall of potting housing 
         ( 30 ,  32 ) two opposed side walls of the potting housing 
         ( 34 ) cover assembly 
         ( 36 ) top wall of the cover assembly 
         ( 38 ) bottom wall of the cover assembly 
         ( 40 ) open first end of the cover assembly 
         ( 42 ) second end wall of the cover assembly 
         ( 44 ,  46 ) pair of conductor apertures of the cover assembly 
         ( 48 ) fiber aperture of the cover assembly 
         ( 50 ) plurality of optical fibers 
         ( 52 ) closure interface assembly 
         ( 54 ) flange of the closure interface assembly 
         ( 56 ) closure 
         ( 58 ) threaded barrel of closure interface assembly of the plug 
         ( 60 ) nut of the closure interface assembly 
         ( 62 ) port of the cover assembly 
         ( 64 ) anchor for securing tension members 
         ( 66 ,  68 ) conductive brackets 
         ( 70 ,  72 ) first tabbed end of the conductive brackets 
         ( 74 ,  76 ) second tabbed ends of the conductive brackets; conductive contacts; forked shaped conductive tabs 
         ( 78 ,  80 ) end portion of a conductor of the jacketed hybrid electrical optical cable 
         ( 82 ,  84 ) end portion of a conductor that extends out of the second end wall of the cover assembly; secondary conductors 
         ( 86 ) protective over-tubing 
         ( 88 ) aperture in the first tabbed ends of the conductive brackets 
         ( 90 ) heat shrinking sleeve 
         ( 92 ) O-ring 
         ( 94 ) strength members