Patent Description:
Fiber optical communication systems typically use a network of fiber optic cables to transmit large volumes of data. Typical fiber optical connectors include a ferrule that supports an end portion of an optical fiber. When two fiber optical connectors are interconnected, end faces of the ferrules, on each connector, directly oppose one another. Thus, the optical fibers, which are supported by each ferrule, are also directly opposed to each other. Furthermore, springs in each connector bias the optical fibers towards each other when the connectors are in this interconnected state. An optical signal can then be transmitted from one optical fiber to the other optical fiber.

Traditionally, the ferrule is disposed in a ferrule holder carrier, which is then secured to an outer barrel. Conventional outer barrels include a clamp shell arrangement in order to easily fit the barrel around and over the ferrule holder carrier and the cable. Thus, the clamp shell may open in order to move the barrel over and around these components. An outer housing may then be disposed over the clamp shell in order to provide a secure andstable connector assembly.

<Document <CIT> discloses a method of installing a Subscriber Connection (SC) -type push/pull optical fiber connector having a ferrule onto an optical fiber.

Document <CIT> discloses a ruggedized fiber optic connector assembly including a substantially hollow plug housing.

Document <CIT> discloses an optical fiber connector including a gimbal. The optical fiber connector further includes a retention body having a pair of snap hooks configured to engage a pair of recesses of the connector sub-assembly.

It may be desirable to provide a hardened optical fiber connector that overcomes one or more problems of conventional prior art connectors that are recognized by persons having ordinary skill in the art.

A fiber optical connector according to the invention is disclosed in any one of appended claims <NUM>-<NUM>.

The present disclosure is directed to a fiber optical connector that can be easily assembled in the field. The fiber optical connector includes a barrel, one or more latches, and a ferrule housing sub-assembly. The barrel includes an inner lumen that is configured to receive an optical fiber cable, and the barrel has a first end and a second end. The one or more latches extend from the first end of the barrel. Additionally, the ferrule housing sub-assembly includes a ferrule holder carrier that is configured to receive a ferrule. The latches engage with the ferrule holder carrier in order to secure the barrel with the ferrule housing sub-assembly.

Features and advantages of the present disclosure are described in, and will be apparent from, the following Brief Description of the Drawings and Detailed Description.

Throughout the description, like reference numerals will refer to like parts in the various drawing figures. As a preface to the detailed description, it should be noted that, as used in this specification and the appended claims, the singular forms "a", "an" and "the" include plural referents, unless the context clearly dictates otherwise.

<FIG> illustrate an exemplary hardened fiber optical connector <NUM> in accordance with various aspects of the disclosure. As shown in <FIG>, the connector <NUM> includes an inner housing <NUM>, a preterminated fiber optic cable <NUM>, a boot <NUM>, a shroud <NUM>, and a coupling nut <NUM>. The preterminated fiber optic cable <NUM> may be, for example, a Miniflex® QuikPush® fiber cable, as illustrated and described in<CIT>.

As illustrated in <FIG>, the inner housing <NUM> extends from a first end <NUM> to a second end <NUM> along a longitudinal axis X and includes a barrel portion <NUM>, a mid-section <NUM>, a latching portion <NUM>, and a connector shell portion <NUM>. The connector shell portion <NUM> is at the first end <NUM> of the inner housing <NUM>, the barrel portion <NUM> is at the second end <NUM> of the inner housing <NUM>, and the mid-section <NUM> and latching portion <NUM> are between the connector shell portion <NUM> and the barrel portion <NUM> in the longitudinal direction.

As illustrated in <FIG>, the barrel portion <NUM> includes a reduced diameter portion 25a and one or more barbs <NUM> configured to couple with the boot <NUM>. The barrel portion <NUM> includes a throughbore 25b extending in the longitudinal direction. The throughbore 25b is configured to receive the preterminated fiber optic cable <NUM> and allow the preterminated cable <NUM> to pass therethrough into the connector shell portion <NUM>. As shown in <FIG> and <FIG>, the barb <NUM> may include a ridge that projects radially outward from the second end <NUM> of inner housing <NUM>. In some embodiments, one barb <NUM> may be provided on barrel portion <NUM>. In other embodiments, two or more barbs <NUM> may be provided on barrel portion <NUM>. It is also contemplated that the barb <NUM> may include any other well-known method to secure boot <NUM> with the barrel portion <NUM>. As shown in <FIG>, boot <NUM> may be disposed over and around the barb <NUM>. The boot <NUM> may be a flexible member that allows an interface between connector <NUM> and optical fiber cable <NUM> to bend and rotate. For example, the boot <NUM> may be formed from a flexible material such as KRAYTON.

The preterminated fiber optic cable <NUM> includes a fiber optic cable <NUM> preterminated by a fiber connector <NUM>, which includes a ferrule <NUM>, and a ferrule holder <NUM>, as would be understood by persons of ordinary skill in the art. The optical fiber cable <NUM> holds a single strand of <NUM> diameter single mode optical fiber 31a, which may be protected by buffering layers and an outer sheath. The optical fiber 31a is held in a bore of the ferrule <NUM>, as would be understood by persons skilled in the art. The fiber connector <NUM> may be, for example, a PPC® Balistix (QuikPush®) connector. The ferrule holder <NUM> includes a neck portion <NUM> formed by an annular groove <NUM> between a first end portion <NUM> and a second end portion <NUM> of the ferrule holder <NUM>. The ferrule <NUM> extends from the first end portion <NUM> of the ferrule holder <NUM>. The inner housing <NUM> is configured to be coupled with the fiber connector <NUM>, as will be described in more detail below.

As best shown in <FIG>, <FIG>, and <FIG>, the mid-section <NUM> includes a portion 26a having an enlarged dimension in the longitudinal direction and having radially-extending flats 26b. The enlarged portion 26a and the flats 26b are configured to align the inner housing <NUM> with the shroud <NUM>, as would be understood by persons of ordinary skill in the art. The mid-section <NUM> includes a throughbore 26b that continues from the throughbore 25b of the barrel portion <NUM> with a substantially same inside diameter.

The connector shell portion <NUM> is configured to be received by a mating optical fiber receptacle or socket. The connector shell portion <NUM> may be configured to be received by a receptacle that is configured to receive a connector having convenient push/pull style mating that allows for push/pull engagement/disengagement between the connector <NUM> and the mating optical fiber socket. For example, in some aspects, the receptacle may be configured to receive a "Subscriber Connector," or SC connector, as originally developed by NTT®, which is well-known by persons having ordinary skill in the art.

As best illustrated in <FIG>, the latching portion <NUM> may be disposed at the mid-section <NUM> of the inner housing <NUM>. The latching portion <NUM> includes one or more latches <NUM> that extend radially inward into the throughbore 26c of the mid-section <NUM> of the inner housing <NUM>. As shown in <FIG> and <FIG>, the latch <NUM> is configured to extend into the annular groove forming the neck portion <NUM> of the ferrule holder <NUM>. Although <FIG> illustrate a single latch <NUM>, the latching portion may include two latches <NUM>, <NUM>' equidistantly arranged around a circumference of the mid-section <NUM>, as shown in <FIG>. Alternatively, the latching portion <NUM> may include three or more latches. For example, the latching portion <NUM> may include four latches disposed equidistantly around the circumference of mid-section <NUM>. It is further contemplated that latches may be disposed irregularly around the circumference of mid-section <NUM>.

The latch <NUM> is configured as a cantilevered member attached at a first end to the mid-section and having a second free end. The latch <NUM> is configured to move radially outward upon application of an outward force and is configured to return to its position extending into the throughbore 26c of the mid-section <NUM> upon removal of the outward force. As a result of this configuration, the latch <NUM> is configured to provide a snap-fit and/or an interference fit with optical fiber connector sub-assembly <NUM>. For example, the latch <NUM> is configured to be received by the neck portion <NUM> of the ferrule holder <NUM> when the preterminated cable <NUM> is received by the inner housing <NUM>.

The shroud <NUM> has a first end <NUM> and a second end <NUM>. The first end <NUM> of the shroud <NUM> includes at least one opening (not numbered) defined by shroud <NUM>. The at least one opening extends from a medial portion of the shroud <NUM> to the first end <NUM>. In the illustrated embodiment, the shroud <NUM> includes a pair of openings on opposite sides of the first end <NUM>, thereby defining alignment portions or fingers <NUM>. In some aspects, the alignment fingers <NUM> may have different shapes so that the connector <NUM> and receptacle (not shown) only mate in one orientation. The medial portion of the shroud <NUM> may include a groove <NUM> for seating an O-ring (not shown). The O-ring is configured to provide a weatherproof seal between the connector <NUM> and the receptacle (not shown) or protective cap (not shown) that is configured to cover a front end of the shroud <NUM> and the ferrule <NUM>. The medial portion may also include a shoulder <NUM> that provides a stop for the coupling nut <NUM>. The coupling nut <NUM> has a passageway sized so that it fits over the second end <NUM> of the shroud <NUM> and easily rotates about the medial portion of shroud <NUM>. In other words, the coupling nut <NUM> cannot move beyond the shoulder <NUM>, but the coupling nut <NUM> is able to rotate with respect to shroud <NUM>.

To assemble the connector <NUM>, the coupling nut <NUM>, the shroud <NUM>, and the boot <NUM> are moved over the preconnectorized cable <NUM>. Viewed differently, the preconnectorized cable <NUM> is pushed through the coupling nut <NUM>, the shroud <NUM>, and the boot <NUM> such that coupling nut <NUM> is furthest from the ferrule <NUM> and the boot <NUM> is nearest the ferrule <NUM>. The preconnectorized cable <NUM> is then pushed into the inner housing <NUM> until the first end portion <NUM> of the ferrule holder <NUM> reaches the latching portion <NUM>. The first end portion <NUM> of the ferrule holder <NUM> includes a ramped surface 36a that is configured to urge the latch <NUM> radially outward as the preconnectorized cable <NUM> is further pushed toward the first end <NUM> of the inner housing <NUM>. When the annular groove <NUM> at the neck portion <NUM> of the ferrule holder <NUM> reaches the latch <NUM>, the latch returns to its position extending into the throughbore 26c of the mid-section <NUM> in the absence of the force from the first end portion <NUM> of the ferrule holder <NUM>. The radial surfaces <NUM> that define the groove <NUM> are not configured to urge the latch <NUM> radially outward, but instead are configured to prevent movement of the ferrule holder <NUM> relative to the inner housing <NUM> in the longitudinal direction. The boot <NUM> is then pushed over the barb <NUM> and onto the reduced diameter portion 25a at the second end <NUM> of the barrel portion <NUM> of the inner housing <NUM> to the position shown in <FIG> and <FIG>. Next, the shroud <NUM> and coupling nut <NUM> are pushed over the boot <NUM> and inner housing <NUM> to reach their positions shown in <FIG>. In some aspects, the boot <NUM> may include one or more retention members <NUM> that extend from an outer surface <NUM> of the boot and are configured to be compressed onto the outer surface <NUM> of the boot <NUM> by the shroud <NUM> as the shroud is moved over the boot <NUM> and inner housing <NUM>. The shroud <NUM> and coupling nut <NUM> may be pushed together or separately.

<FIG> illustrate another exemplary hardened fiber optical connector <NUM> in accordance with various aspects of the disclosure. As shown in <FIG>, the connector <NUM> includes an inner housing <NUM>, a preterminated fiber optic cable <NUM>, a shroud <NUM>, and a coupling nut <NUM>. The preterminated fiber optic cable <NUM> may be, for example, a Miniflex® QuikPush® fiber cable, as illustrated and described in <CIT>.

As illustrated in <FIG>, the inner housing <NUM> extends from a first end <NUM> to a second end <NUM> along a longitudinal axis X and includes a rear portion <NUM>, a mid-section <NUM>, a latching portion <NUM>, and a connector shell portion <NUM>. The connector shell portion <NUM> is at the first end <NUM> of the inner housing <NUM>, the rear portion <NUM> is at the second end <NUM> of the inner housing <NUM>, and the mid-section <NUM> and latching portion <NUM> are between the connector shell portion <NUM> and the rear portion <NUM> in the longitudinal direction.

As illustrated in <FIG>, the rear portion <NUM> includes a reduced diameter portion 125a having one or more barbs <NUM> configured to couple with a retention structure <NUM> of the shroud <NUM>. The rear portion <NUM> includes a throughbore 125b extending in the longitudinal direction. The throughbore 125b is configured to receive the preterminated fiber optic cable <NUM> and allow the preterminated cable <NUM> to pass therethrough into the connector shell portion <NUM>.

The preterminated fiber optic cable <NUM> includes a fiber optic cable <NUM> preterminated by a fiber connector <NUM>, which includes a ferrule <NUM>, and a ferrule holder <NUM>, as would be understood by persons of ordinary skill in the art. The optical fiber cable <NUM> holds a single strand of <NUM> diameter single mode optical fiber (not shown), which may be protected by buffering layers and an outer sheath. The optical fiber (not shown) is held in a bore of the ferrule <NUM>, as would be understood by persons skilled in the art. The fiber connector <NUM> may be, for example, a PPC® Balistix (QuikPush®) connector. The ferrule holder <NUM> includes a neck portion <NUM> formed by an annular groove <NUM> between a first end portion <NUM> and a second end portion <NUM> of the ferrule holder <NUM>. The ferrule <NUM> extends from the first end portion <NUM> of the ferrule holder <NUM>. The inner housing <NUM> is configured to be coupled with the fiber connector <NUM>, as will be described in more detail below.

A clip 126a may be removably coupled with the mid-section <NUM>. The removable clip 126a has an enlarged radial dimension relative to the mid-section <NUM> and includes transversely-extending flats 126b. The removable clip 126a and the flats 126b are configured to align the inner housing <NUM> with the shroud <NUM>, as would be understood by persons of ordinary skill in the art. The mid-section <NUM> includes a throughbore 126b that continues from the throughbore 125b of the rear portion <NUM> with a substantially same inside diameter.

As best illustrated in <FIG>, the latching portion <NUM> may be disposed at the mid-section <NUM> of the inner housing <NUM>. The latching portion <NUM> includes one or more latches <NUM> that extend radially inward into the throughbore 126b of the mid-section <NUM> of the inner housing <NUM>. The latch <NUM> is configured to extend into the annular groove forming the neck portion <NUM> of the ferrule holder <NUM>. Although <FIG> illustrate a single latch <NUM>, the latching portion <NUM> may include two or more latches, as described above.

The latch <NUM> is configured as a cantilevered member attached at a first end to the mid-section and having a second free end. The latch <NUM> is configured to move radially outward upon application of an outward force and is configured to return to its position extending into the throughbore 126b of the mid-section <NUM> upon removal of the outward force. As a result of this configuration, the latch <NUM> is configured to provide a snap-fit and/or an interference fit with optical fiber connector sub-assembly <NUM>. For example, the latch <NUM> is configured to be received by the neck portion <NUM> of the ferrule holder <NUM> when the preterminated cable <NUM> is received by the inner housing <NUM>.

To assemble the connector <NUM>, the coupling nut <NUM> and the shroud <NUM> are moved over the preconnectorized cable <NUM>. Viewed differently, the preconnectorized cable <NUM> is pushed through the coupling nut <NUM> and the shroud <NUM> such that the coupling nut <NUM> is further from the ferrule <NUM>. The preconnectorized cable <NUM> is then pushed into the inner housing <NUM> until the first end portion <NUM> of the ferrule holder <NUM> reaches the latching portion <NUM>. The first end portion <NUM> of the ferrule holder <NUM> includes a ramped surface 136a that is configured to urge the latch <NUM> radially outward as the preconnectorized cable <NUM> is further pushed toward the first end <NUM> of the inner housing <NUM>. When the annular groove <NUM> at the neck portion <NUM> of the ferrule holder <NUM> reaches the latch <NUM>, the latch returns to its position extending into the throughbore 126b of the mid-section <NUM> in the absence of the force from the first end portion <NUM> of the ferrule holder <NUM>. The radial surfaces <NUM> that define the groove <NUM> are not configured to urge the latch <NUM> radially outward, but instead are configured to prevent movement of the ferrule holder <NUM> relative to the inner housing <NUM> in the longitudinal direction. The shroud is then pushed over the barbs <NUM> at the second end <NUM> of the rear portion <NUM> and over the inner housing <NUM> to the position shown in <FIG>. Next, the coupling nut <NUM> is pushed over the shroud <NUM> to reach its position shown in <FIG>. The shroud <NUM> and coupling nut <NUM> may be pushed together or separately.

The foregoing description of exemplary embodiments provides illustration and description, but is not intended to be exhaustive or to limit the embodiments described herein to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from practice of the embodiments.

Although the invention has been described in detail above, it is expressly understood that it will be apparent to persons skilled in the relevant art that the invention may be modified without departing from the scope of the invention. Various changes of form, design, or arrangement may be made to the invention without departing from the scope of the invention. Therefore, the above mentioned description is to be considered exemplary, rather than limiting, and the scope of the invention is that defined in the following claims.

Claim 1:
A fiber optical connector (<NUM>; <NUM>) comprising:
a barrel portion (<NUM>) that includes an inner lumen configured to receive an optical fiber cable (<NUM>), the barrel portion (<NUM>) having a first end and a second end,
wherein the second end of the barrel portion (<NUM>) includes a barb (<NUM>) that projects outward from the second end of the barrel portion (<NUM>);
a boot (<NUM>), wherein the barb (<NUM>) of the barrel portion (<NUM>) is configured for attachment to the boot (<NUM>);
one or more latches (<NUM>) extending from the first end of the barrel portion (<NUM>); and
a ferrule housing sub-assembly that includes a ferrule holder (<NUM>) that is configured to receive a ferrule (<NUM>), wherein the latches (<NUM>) engage with the ferrule holder (<NUM>) in order to secure the barrel portion (<NUM>) with the ferrule housing sub-assembly;
a coupling nut (<NUM>); and
a shroud (<NUM>) having a first end (<NUM>) and a second end (<NUM>), wherein the first end (<NUM>) of the shroud (<NUM>) includes at least one opening defined by the shroud (<NUM>) and extending from a medial portion of the shroud (<NUM>) to the first end (<NUM>),
wherein the medial portion of the shroud (<NUM>) includes a shoulder (<NUM>) that provides a stop for the coupling nut (<NUM>),
and wherein the coupling nut (<NUM>) has a passageway sized so that it fits over the second end (<NUM>) of the shroud (<NUM>) and rotates about the medial portion of shroud (<NUM>), wherein the coupling nut (<NUM>) cannot move beyond the shoulder (<NUM>), but the coupling nut (<NUM>) is able to rotate with respect to shroud (<NUM>).