Patent Publication Number: US-2015063758-A1

Title: Gang fiber adaptor with integral mounting features

Description:
RELATED APPLICATIONS 
     This application claims the benefit of priority under 35 U.S.C. §119 of U.S. Provisional Application No. 61/872,108 filed on Aug. 30, 2013, the content of which is relied upon and incorporated herein by reference it its entirety. 
    
    
     BACKGROUND 
     1. Field of the Disclosure 
     The disclosure relates generally to optical fiber adaptors, and more particularly to gang optical fiber adaptors or adaptor banks which may be used in fiber optic distribution frames located in structures such as, for example, central offices or fiber optic local convergence points like outdoor cabinets. 
     2. Technical Background 
     In fiber optic network apparatus including convergence points and distribution frames there is a constant demand for apparatus permitting high-density distribution with very high fiber termination counts in a small, confined volume. To accomplish the high-density distribution with high fiber termination counts requires efficient utilization of space with due regard to constraints put on fiber optic cables such as minimum bending radii. Optical fiber adaptors or adaptor banks may be used to accomplish the high fiber termination counts in fiber optic distribution frames located in structures such as, for example, central offices or fiber optic local convergence points like outdoor cabinets. 
     SUMMARY 
     One embodiment of the disclosure relates to an adaptor that comprises a body that includes a pair of opposed short sides having a length (l) and a pair of opposed long sides having a length (L). The pair of opposed short sides and the pair of opposed long sides define an axial cavity of the adaptor. A portion of a ferrule alignment structure is molded within the axial cavity and configured to receive a remaining portion of the ferrule alignment structure. The adaptor is molded as a single, integral assembly 
     An additional embodiment of the disclosure relates to a gang adaptor assembly that comprises a body including a front end, a rear end, a top wall, a bottom wall, a first side wall, and a second side wall. The body also has a plurality of interior side walls disposed between and parallel to the first side wall and the second side wall. The top wall, the bottom wall, the first side wall, the second side wall, and the plurality of interior side walls define a plurality of axial cavities extending from the front end to the rear end of the body, and each of the plurality of axial cavities corresponds to one of a plurality of adaptors. Each of the plurality of adaptors shares at least one of the plurality of interior side walls with an adjacent adaptor. At least a portion of a ferrule alignment structure is molded within each of the plurality of adaptors. The at least a portion of the ferrule alignment structure comprises at least a ferrule holder. The gang adaptor assembly also comprises a first mounting feature that is molded into a face of the first side wall external to the plurality of adaptors, and a second mounting feature molded into a face of the second side wall external to the plurality of adaptors. 
     An additional embodiment of the disclosure relates to a method of manufacturing a gang adaptor assembly that comprises molding the gang adaptor assembly as a single, integral piece. The gang adaptor assembly comprises a front end, a rear end, a top wall, a bottom wall, a first side wall, a second side wall, and a plurality of interior side walls disposed between and parallel to the first side wall and the second side wall. The top wall, the bottom wall, the first side wall, the second side wall, and the plurality of interior side walls define a plurality of axial cavities that extend from the front end to the rear end of the body, and each of the plurality of axial cavities correspond to one of a plurality of adaptors. A portion of a ferrule alignment structure is molded within each of the plurality of adaptors. Additionally, a set of mounting features extends from the first and second side walls to connect the gang adaptor assembly to a cassette. The method also includes inserting a remaining portion of the ferrule alignment structure into each of the plurality of adaptors. The remaining portion of the ferrule alignment structure is configured to snap into each of the plurality of adaptors. 
     Additional features and advantages will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from the description or recognized by practicing the embodiments as described in the written description and claims hereof, as well as the appended drawings. 
     It is to be understood that both the foregoing general description and the following detailed description are merely illustrative, and are intended to provide an overview or framework to understand the nature and character of the claims. 
     The accompanying drawings are included to provide a further understanding, and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiment(s), and together with the description serve to explain principles and operation of the various embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a right front perspective view of a gang adaptor assembly according to one or more embodiments shown or described herein; 
         FIG. 2  is a right front perspective view of a gang adaptor assembly having a different set of mounting features according to one or more embodiments shown or described herein; 
         FIG. 3  is a right front perspective view of a gang adaptor assembly having yet a different set of mounting features according to one or more embodiments shown or described herein; 
         FIG. 4  is a left rear perspective view of the gang adaptor assembly of  FIG. 1  according to one or more embodiments shown or described herein; 
         FIG. 5  is a right front perspective view of the gang adaptor assembly of  FIG. 1  connected to a optical fiber cassette according to one or more embodiments shown or described herein; 
         FIG. 6  is an exploded view of a ferrule alignment structure to be inserted into each adaptor in the gang adaptor assembly according to one or more embodiments shown or described herein; 
         FIG. 7  is a detail of a right front perspective view of a second end of the gang adaptor assembly of  FIG. 1  according to one or more embodiments shown or described herein; and 
         FIG. 8  is a right front perspective cross-sectional view of the adaptor of the gang adaptor assembly of  FIG. 7  shown along line  8 - 8  according to one or more embodiments shown or described herein. 
     
    
    
     DETAILED DESCRIPTION 
     Various embodiments will be further clarified by the following examples. 
     Referring to  FIGS. 1-4 , an example of a gang adaptor assembly is shown as  10 . Gang adaptor assembly  10  includes twenty-four (24) adaptors  12   a - 12   x  connected together. Gang adaptor assembly  10  includes a first end  14  and a second end  16  opposite first end  14  along a longitudinal axis L-L′. Gang adaptor assembly  10  also includes a top wall  18  extending between first and second ends  14  and  16 , respectively, a bottom wall  20  extending between first and second ends  14  and  16 , respectively, on a side of gang adaptor assembly  10  opposite top wall  18 , a front end  22  extending between first and second ends  14  and  16 , respectively, and a rear end  24 , extending between first and second ends  14  and  16 , respectively, on a side of gang adaptor assembly  10  opposite front end  22 . First end  14  includes a first side wall  26  and second end  16  includes a second side wall  28 . First and second side walls  26  and  28  extend between top wall  18  and bottom wall  20  and between front end  22  and rear end  24 . Similarly, a plurality of interior side walls  30  are disposed between and parallel to first and second side walls  26  and  28 , extending between top wall  18  and bottom wall  20  and between front end  22  and rear end  24 . 
     Each adaptor  12   a - 12   x  is configured to receive an individual optical fiber by conventional methods. Adaptors  12   a - 12   x  may receive any conventional optical fiber connector for connecting to optical fibers such as, for example, SC connectors, LC connectors, ST connectors, FC connectors, E2000 connectors, and any other optical fiber connectors. As shown in this example, adaptors  12   a - 12   x  are configured to receive SC connectors. However, in the embodiment shown, the adaptors  12   a - 12   x  are aligned so that the long sides of adjacent adaptors interface. In this manner, more adaptors can be ganged in a certain length such that gang adaptor assembly  10  permits 24 adaptors to be ganged together in one optical fiber cassette  500  as shown in  FIG. 5 . 
     In this regard, adaptors  12   a - 12   x  each have a body  32 , wherein body  32  includes a first short side  34   a,  a second short side  34   b  opposite first short side  34   a,  a first long side  36   a,  a second long side  36   b  opposite first long side  36   a,  and an axial cavity  38  disposed through body  32  between the four walls. In various embodiments, the first short side  34   a  for each of the adaptors  12   a - 12   x  is connected as top wall  18  from which each of the long sides (including first long side  36   a  and second long side  36   b ) extend. Similarly, the second short side  34   b  for each of the adaptors  12   a - 12   x  is connected as bottom wall  20  from which each of the long sides extend. Thus, the long sides (e.g., first side wall  26 , second side wall  28 , and plurality of interior side walls  30 ) interface to divide the top and bottom walls into the first and second short sides  34   a  and  34   b  to define the body  32  for each of the adaptors  12   a - 12   x.  Axial cavity  38  is configured and operable to receive and connect to an optical fiber inserted therein. First and second short sides  34   a  and  34   b,  respectively, have a length (l), and first and second long sides  36   a  and  36   b,  respectively, have a length (L). Length (L) is greater than length (l). 
     Adaptors  12   a - 12   x  are disposed side-by-side along longitudinal axis L-L′ to form gang adaptor assembly  10 . As shown, the adaptors  12   a - 12   x  are positioned such that the adaptor&#39;s long sides are adjacent to each other or connected to each other and are transverse to longitudinal axis L-L′. In this configuration, first and second short sides  34   a  and  34   b,  respectively, are parallel to longitudinal axis L-L′. For example, a second long side  36   b  of first adaptor  12   a  is positioned adjacent to first long side  36   a  of second adaptor  12   b.  This configuration permits a dense adaptor configuration on the optical fiber cassette  500  such as shown, for example, in  FIG. 5 . In various embodiments, each of the adaptors may share at least one long side with an adjacent adaptor. For example, a second long side  36   b  of first adaptor  12   a  may be the same interior side wall  30  that is first long side  36   a  of second adaptor  12   b.  This configuration may also permit a dense adaptor configuration on the optical fiber cassette  500 . In other embodiments, each adaptor may include at least one connecting feature configured to connect the adaptor to another, adjacent adaptor. Adaptors may be connected using any conventional or yet-to-be developed connecting features, including but not limited to snap-fit connections. The connecting features may be located on opposing long sides or on opposing short sides of the adaptors, depending on the particular implementation. Some adaptors may include a pair of connecting features, one on each opposing long sides, while other adaptors may include a single connecting features, such as on one of the opposing long sides, and a mounting feature (e.g., a mounting feature configured to connect the adaptor to a cassette or other device within fiber optic distribution frames), such as on the other opposing long side. Still other adaptors may include a pair of mounting features, one on each opposing long side. 
     As shown in  FIGS. 1-3 , the gang adaptor assembly  10  can include a set of mounting features extending from the first side wall  26  and the second side wall  28 . The mounting features can enable the gang adaptor assembly  10  to connect to optical fiber cassette  500 , a rack-mount housing, or a fiber distribution hub (FDH) cabinet. The mounting features illustrated in  FIG. 1  enable the gang adaptor assembly  10  to connect to the optical fiber cassette  500  and is shown and described in copending, commonly owned U.S. Provisional Patent Application Ser. No. 61/825,779, filed May 21, 2013, which is hereby incorporated by reference in its entirety. In particular, a stem (not shown) extends from a face of the first side wall  26  external to the adaptors  12   a - 12   x  of gang adaptor assembly  10 , along longitudinal axis L-L′, and a head  40   a  is positioned on a distal end of the stem and extends transverse to the stem and longitudinal axis L-L′. Also, a stem  42  extends from a face of the second side wall  28  external to the adaptors  12   a - 12   x  of gang adaptor assembly  10  along longitudinal axis L-L′, opposite first side wall  26 . A head  40   b  is positioned on a distal end of stem  42  and extends transverse to stem  42  and the longitudinal axis. It is understood that the stem and head  40   a  extending from first side wall  26  is the same as or similar to stem  42  and head  40   a.  In this example, gang adaptor assembly  10  is molded as an integral piece from a polymer material, composite material, or any combination thereof. An example of a polymer material that may be used is polycarbonate, UItem. However, it is understood that gang adaptor assembly  10  may be manufactured from one or more pieces that may be connected together using conventional methods such as for example, welding (e.g., hot weld, sonic welds, etc.), snap-fit connections, screws, bolt and nut connections, etc. 
     The mounting features illustrated in  FIG. 2  enable the gang adaptor assembly  10  to connect to a rack-mount housing. As in  FIG. 1 , the gang adaptor assembly  10  depicted in  FIG. 2  includes a first end  14 , a second end  16 , a top wall  18 , a bottom wall  20 , a front end  22 , and a rear end  24 . Gang adaptor assembly  10  also includes a plurality of interior side walls  30  disposed between and parallel to the first side wall  26  and the second side wall  28 . A plate  44  extends from a face of each of the first side wall  26  and the second side wall  28  external to the adaptors  12   a - 12   x.  Each plate  44  includes a mounting hole  46  configured to receive a fastener, such as a pin, screw, or the like, to secure the gang adaptor assembly  10  to the rack-mount housing. It is understood that the mounting hole  46  may be a substantially round hole, as depicted in  FIG. 2 , or the mounting hole  46  may have an oval or other shape. As illustrated in  FIG. 2 , each plate  44  extends from the respective first and second side wall  26  and  28  such that the mounting hole  46  extends from the front end  22  to the rear end  24 , parallel to the axial cavity  38  of each adaptor  12   a - 12   x.  However, in some embodiments, the mounting hole  46  may be oriented in other directions, such as perpendicular to the axial cavity  38  of each adaptor  12   a - 12   x.  The orientation and shape of the mounting hole  46  may vary depending on the particular embodiment. In this example, gang adaptor assembly  10  is molded with the mounting features as an integral piece from a polymer material, composite material, or any combination thereof. An example of a polymer material that may be used is polycarbonate, UItem. However, it is understood that gang adaptor assembly  10  may be manufactured from one or more pieces that may be connected together using conventional methods such as for example, welding (e.g., hot weld, sonic welds, etc.), snap-fit connections, screws, bolt and nut connections, etc. 
       FIG. 3  schematically depicts a gang adaptor assembly  10  that includes integrally molded mounting features to enable the gang adaptor assembly  10  to be mounted within a fiber distribution hub (FDH) cabinet. As shown in  FIG. 3 , first end  14  of gang adaptor assembly  10  includes a latch  48  while second end  16  of gang adaptor assembly includes a tab  50 . The latch  48  is designed to removably snap into an opening in a bracket, panel, or other suitable mounting structure, of the FDH cabinet while the tab  50  is engaged in a corresponding opening in the storage panel for a mounting location within the FDH cabinet. Although  FIGS. 1-3  depict mounting features for connecting the gang adaptor assembly  10  to optical fiber cassette  500 , a rack-mount housing, and an FDH cabinet, other mounting features may be integrally molded as part of the gang adaptor assembly  10 . Thus, the gang adaptor assembly  10  may be mounted in, on or to any type of frame, structure or housing. 
     Referring to  FIG. 4 , gang adaptor assembly  10  may include a first latch actuator  52   a  at first end  14  and a second latch actuator  52   b  at second end  16 . First and second latch actuators  52   a  and  52   b  include actuator surfaces  54   a  and  54   b  which correspond with and engage corresponding latch engagement surfaces on latch mechanisms located on an optical fiber cassette  500 . In this example, actuator surfaces  54   a  and  54   b  are arcuate or curved surfaces and the corresponding latch surfaces on the first and second latch mechanisms comprise shapes that correspond to (i.e., are the inverse of) the actuator surfaces  54   a  and  54   b.  However, it is understood that actuator surfaces  54   a  and  54   b  may comprise any shape, configuration, angle, or radius of curvature as long as such surface actuates the corresponding latch mechanism to release the adaptor holder or gang adaptor assembly such that it may rotate or tilt within optical fiber cassette  500  as will be shown and described below herein. In one such alternative example, actuator surfaces  54   a  and  54   b  may be linear, angled surfaces that engage corresponding linear, angled surfaces of the first and second latch mechanisms on optical fiber cassette  500 . 
     Also, gang adaptor assembly  10  may include a first stop  56   a  or a second stop  56   b  disposed along rear end  24  at respective first and second ends  14  and  16 . First stop  56   a  or second stop  56   b  may be configured to prevent gang adaptor assembly  10  from rotating or tilting beyond a specific angular rotation, angle a, about longitudinal axis L-L′. In this example, first stop  56   a  and second stop  56   b  each comprise a stop oriented at an angle α. First and second stop  56   a  and  56   b  are configured to prevent gang adaptor assembly  10  from rotating or tilting past angle a (not shown). Angle a is determined based upon the desired maximum angle of rotation or tilt of gang adaptor assembly  10  about longitudinal axis L-L′. 
     In certain examples, angle a is about 10°, about 15°, about 20°, about 25°, about 30°, about 35°, about 40°, about 45°, about 50°, about 55°, about 60°, about 65°, about 70°, about 75°, about 80°, about 85°, or about 90°. In such embodiment, gang adaptor assembly  10  may rotate or tilt between a starting position angular orientation (e.g.,0°) and angle α. In other embodiments gang adaptor assembly  10  may be configured to rotate or tilt 360° about axis L-L′. 
     As shown in  FIG. 5 , gang adaptor assembly  10  may be fixedly, movably, or removably connected to a framework  58  of optical fiber cassette  500  as will be explained below herein. In this example, gang adaptor assembly  10  is rotatably connected to framework  58  such that gang adaptor assembly  10  may rotate or tilt about longitudinal axis L-L′ in a counterclockwise direction or clockwise direction. In addition, optical fiber cassette  500  may be configured to be removably inserted into or mounted to a tray, frame, chassis, housing, enclosure, rack or any other structure as conventionally known. 
     Optical fiber cassette  500  includes a framework  58  operable for receiving, routing, managing and storing optical fibers, optical fiber connections and optical components. Optical fiber cassette  500  is operable to slide into and out of a fiber optic distribution frames or cabinets. Framework  58  includes a first head slot  60   a  disposed within framework  58  at a first framework side  62  of framework  58  to receive head  40   a  and stem (not sown) located on first end  14  of gang adaptor assembly  10 . Additionally, framework  58  includes a second head slot  60   b  disposed within framework  58  at a second framework side  64  of framework  58  to receive head  40   b  and stem  42  located on second end  16  of gang adaptor assembly  10 . The above described connection points between the gang adaptor assembly  10  and optical fiber cassette  500  permit gang adaptor assembly  10  to rotate or tilt in a counter-clockwise direction or a clockwise direction about an axis L-L′ such as, for example, those shown and described in copending, commonly owned U.S. Provisional Patent Application Ser. No. 61/825,779, filed May 21, 2013, which is hereby incorporated by reference in its entirety. 
     In the example shown in  FIGS. 1-5 , gang adaptor assembly  10  includes 24 adaptors  12   a - 12   x  for receiving SC connectors. However, a variety of designs, adaptors and configurations may be used with the rotatable connection as shown and described herein. As such, any type and number of adaptors may be ganged and connected to a cassette such as, for example, those shown and described in copending, commonly owned U.S. Provisional Patent Application Ser. No. 61/825,779, filed May 21, 2013, which is hereby incorporated by reference in its entirety. 
     Each adaptor  12   a - 12   x  further includes a ferrule alignment structure  66 , shown in  FIG. 6 . In the embodiment shown in  FIG. 6 , ferrule alignment structure  66  includes four flexible arms  68   a,    68   b,    68   c,  and  68   d  that flex to enable ferrule alignment structure  66  to be inserted into an axial cavity  38  of one of the adaptors  12   a - 12   x.  Ferrule alignment structure  66  also includes a first ferrule holder  70  and a second ferrule holder  72 . First and second ferrule holders  70  and  72  form a mounting sleeve that is configured to receive a ferrule sleeve  74  into which ferrules are inserted. In various embodiments, ferrule sleeve  74  includes a slit  76  for allowing ferrule sleeve  74  to compress and reduce its diameter during insertion into the ferrule alignment structure. Ferrule sleeve  74  may be inserted into the mounting sleeve through either first ferrule holder  70  or second ferrule holder  72 . 
     In various embodiments, at least a portion of the ferrule alignment structure  66  is molded within the axial cavity  38  as an integral piece of each of the adaptors  12   a - 12   x.    FIGS. 7-8  schematically depict a number of the adaptors  12   a - 12   x  of the gang adaptor assembly  10  of  FIGS. 1-5  in greater detail. As shown in  FIG. 7 , the adaptors  12   a - 12   x  each have an axial cavity  38  disposed through body  32  between the four walls as shown and described above. In various embodiments, at least a portion of a ferrule alignment structure  66  is molded within the axial cavity  38  of each adaptor  12   a - 12   x,  shown in the cross-sectional view of the axial cavity  38  schematically depicted in  FIG. 8 . For example, as shown in  FIG. 8 , first ferrule holder  70  is molded within the axial cavity  38  of each adaptor  12   a - 12   x.  Though first ferrule holder  70  is illustrated as being molded within axial cavity  38 , additional or alternative portions of the ferrule alignment structure  66  may be molded within the axial cavity  38 . In various embodiments, less than the whole ferrule alignment structure  66  is molded within the axial cavity  38 , although in some embodiments, the whole ferrule alignment structure  66  may be molded within the axial cavity  38 . 
     When a portion of the ferrule alignment structure  66  is molded within the axial cavity  38 , the axial cavity  38  is further molded such that it is configured to receive the remaining portion  78  of the ferrule alignment structure  66 , including the second ferrule holder  72 . The axial cavity  38 , and the portion of the ferrule alignment structure  66  molded therein, may be configured to receive the remaining portion  78  of the ferrule alignment structure  66  in a snap-fit connection. When the remaining portion  78  of the ferrule alignment structure  66  is inserted into the axial cavity  38 , tabs  80   a  and  80   b  on the exterior sides between flexible arms  68   a  and  68   c  and  68   b  and  68   d,  respectively, are pushed inwardly by the first short side  34   a  and second short side  34   b  of body  32 , permitting the remaining portion  78  of the ferrule alignment structure  66  to slide into the axial cavity  38 . Once the tabs  80   a  and  80   b  reach the channels  82   a  and  82   b  disposed within the first short side  34   a  and the second short side  34   b  respectively, the tabs  80   a  and  80   b  move, flex, or snap back outwardly into the channels  82   a  and  82   b.  When tabs  80   a  and  80   b  are within respective channels  82   a  and  82   b,  the remaining portion  78  of the ferrule alignment structure  66  is locked into its position within the axial cavity  38 . As such, the remaining portion  78  is connected to, locked into, or “snapped” into axial cavity  38 . 
     Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that any particular order be inferred. 
     Many modifications and other embodiments set forth herein will come to mind to one skilled in the art to which the embodiments pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the description and claims are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.