Patent ID: 12222572

DETAILED DESCRIPTION

Reference will now be made in detail to exemplary aspects of the present invention which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or similar parts.

FIGS.1-7illustrate a telecommunications assembly10that includes a telecommunications chassis12and a plurality of fiber optic splitter modules14adapted to be mounted within chassis12. Fiber optic splitter modules14are configured to be slidably inserted within chassis12and be optically coupled to adapter assemblies16mounted within chassis12. Adapter assemblies16mounted within chassis12form connection locations between connectors terminated to an incoming fiber optic cable and connectors of splitter modules14as will be discussed in further detail below.

Still referring toFIGS.1-7, chassis12includes a top wall18and a bottom wall20extending between a pair of opposing transverse sidewalls,22,24. Chassis12includes an opening26through a rear side28of chassis12and an opening through a front side32of chassis12. Fiber optic splitter modules14are inserted into chassis12through front opening30. Adapter assemblies16are inserted through and mounted adjacent rear opening26of chassis12. Sidewalls22,24, each include a cut-out34extending from front opening30toward rear side28. Splitter modules14mounted within chassis12are visible through cut-out34. Sidewalls22,24of chassis12also define an inset portion36at rear side28of chassis12to facilitate access to adapter assemblies16.

InFIG.1, chassis12is shown with eight fiber optic splitter modules14mounted thereon. It should be noted that in other embodiments, the chassis may be sized to hold a larger or a smaller number of splitter modules.

Still referring toFIGS.1-7, chassis12includes a plurality of mounting locations38for slidably receiving splitter modules14. Each mounting location38defines a slot40adjacent top wall18and a slot42adjacent bottom wall20of chassis12. Slots42adjacent bottom wall20are visible inFIG.1. Slots40adjacent top wall18are illustrated inFIGS.36and37. Slots40,42extend from front32of chassis12to rear28of chassis12. Slots40,42are configured to receive mounting flanges44,46of splitter modules14as shown inFIGS.36and37to align modules14with other components within chassis12(e.g., adapters of the adapter assemblies) to mate with pre-connectorized and/or pre-installed transmission cables.

Slots40defined underneath top wall18of chassis12are deeper than slots42defined at bottom wall20of chassis12. The depth of slots40,42are configured to accommodate the different sized flanges44,46that are defined at top and bottom walls of splitter modules14. In this manner, slots40,42and mounting flanges44,46of fiber optic splitter modules14provide a keying system to ensure that modules14are inserted into chassis12in the correct orientation.

Slots40underneath top wall18of chassis12are defined between a plurality of bulkheads48(please seeFIGS.36and37). Bulkheads48extend from front32of chassis12to rear28of chassis12. At front end32of chassis12, each bulkhead48defines a downwardly extending front lip50(FIG.35) which interlocks with a resiliently deformable latch52(e.g., cantilever arm) of splitter module14to hold splitter module14in place within chassis12, as will be discussed in further detail below.

Referring toFIGS.1and7, at rear end28of chassis12, each bulkhead48defines a rear face54with a fastener hole56for receiving a fastener58(e.g., a thumbscrew) of an adapter assembly16for mounting adapter assembly16to chassis12. In the embodiment shown, fastener hole56is threaded to receive a screw-type fastener. It should be noted that in other embodiments, other types of fastening structures may be used to mount adapter assembly16to rear28of chassis12.

Adjacent rear end28, each bulkhead48also includes a horizontal slot60and a vertical slot62that complement the shape of adapter assembly16to slidably receive adapter assembly16.

FIGS.8-15illustrate adapter assembly16according to the invention. Adapter assemblies16form connection locations between the connectors terminated to an incoming fiber optic cable and the connectors of splitter modules14mounted within chassis12.

Referring toFIGS.8-15, adapter assembly16includes two integrated adapters64formed as a part of a unitary housing66. In other embodiments, other number of adapters are also possible. Each adapter64of adapter assembly16includes a front end68and a rear end70. Front end68of each adapter64receives a connector of fiber optic splitter module14and rear end70receives a connector terminated to an incoming fiber optic cable.

Adapter assembly housing66includes a chassis-mounting slide72extending from a top74of housing66, which is received within chassis12through rear end28. Slide72defines a horizontal portion76and a vertical portion78. Horizontal portion76is configured to be slidably received within horizontal slot60of bulkhead48and vertical portion78is configured to be slidably received within vertical slot62of bulkhead48.

Chassis-mounting slide72includes a pair of flanges80for supporting a fastener58for securing adapter assembly16to chassis12. As discussed earlier, fastener58is positioned within an opening56defined by rear face54of bulkheads48located underneath top wall18of chassis12. Fastener58is preferably a captive fastener. In the embodiment of the adapter assembly shown in the FIGS., fastener58is a thumbscrew. In other embodiments, other types of fasteners may be used.

Fastener58is rotated to threadingly couple the adapter assembly16to the bulkheads48. Fastener58is also configured such that it is able to provide adapter assembly16with a predetermined amount of horizontal float relative to the chassis12once mounted thereon. As illustrated inFIGS.8-14, the fastener58of the adapter assembly16includes a flange81. The fastener58is able to move horizontally within the flanges80relative to the adapter assembly housing66. As shown inFIG.35, once mounted to the chassis12, the adapter assembly housing66is able to float or move horizontally with respect to the fastener58between flange81and the rear face of the bulkhead48. For example, inFIG.35, adapter assembly16is shown to be able to move or float a distance of A toward the rear end of chassis12. In this manner, when a splitter module14is slidably pulled out of chassis12during disengagement, adapter assembly16is able to horizontally float a distance A towards splitter module14as the engaged connector118of splitter module14pulls on adapter64of adapter assembly16. In this manner, adapter assembly16is provided with a certain amount of horizontal float when being engaged to and disengaged from splitter module14.

As shown in an exploded view of adapter assembly16inFIG.38, elements of each adapter64are positioned through a side opening82into adapter recesses84formed within the adapter assembly housing66. The elements for each adapter64include a ferrule alignment sleeve86and a pair of inner housing halves88. These elements are placed within recesses84in manner similar to that shown in commonly-owned U.S. Pat. No. 5,317,663, issued May 20, 1993, entitled ONE-PIECE SC ADAPTER, the disclosure of which is incorporated herein by reference. A panel90closes opening82and secures the elements within each adapter64. Adapters64shown are for SC style connectors, although other types, styles and formats of adapters may be used within the scope of the present disclosure and connectors to mate with these alternative adapters.

InFIGS.16-19, adapter assembly16is shown mounted to a fiber optic splitter module14, outside of chassis12.

FIGS.20-30illustrate one of the fiber optic splitter modules14according to the invention. Referring toFIGS.20-30, the fiber optic splitter module14includes a splitter module housing92. Splitter module housing92includes a main housing portion94and a removable cover96. Main housing portion94includes a first transverse sidewall98extending between a top wall100, a bottom wall102, a rear wall104, and a front wall106. Removable cover96defines a second transverse wall108of splitter module housing92and closes off the open side of module main housing94.

Cover96is mounted to main housing portion94by fasteners (not shown) through fastener mounts110defined on main housing portion94. Cover96extends beyond first transverse sidewall98to form a top mounting flange44and a bottom mounting flange46of splitter module14. Referring toFIGS.23,25, and26, as discussed previously, bottom flange46of splitter module housing92and the corresponding slot42on chassis12are smaller in size than top flange44and the corresponding top slot40on chassis12. Bottom slot42is sized so that, while bottom flange46may be received within slot42, the larger top flange44will not fit. This ensures that modules14are positioned within front opening30in a particular desired orientation. Similar flanges are described in commonly-owned U.S. Pat. No. 5,363,465, issued Nov. 8, 1994, entitled FIBER OPTIC CONNECTOR MODULE, the disclosure of which is incorporated herein by reference. In this manner, fiber optic modules14are oriented correctly to be coupled to adapter assemblies16mounted adjacent rear28of chassis12at each mounting location38.

Rear wall104of main housing portion94includes a curved portion112configured to provide bend radius protection to cables within interior114. Rear wall104of main housing92also includes an inset portion116. A pair of fiber optic connectors118positioned at inset portion116protrude rearwardly from rear wall104for mating with fiber optic adapters64of adapter assemblies16mounted within chassis12.

As shown inFIGS.5and6, front wall106of module main housing94is angled with regard to front opening30of chassis12, which may aid in the direction of cables exiting module14toward a desired location. In other embodiments, front walls106could be made generally parallel to front32of chassis12within the scope of the present disclosure.

Each module14includes two cable exits120extending from front wall106of module main housing94. As shown inFIG.22, cable exits120are slidably mounted to main housing94of module14and captured by cover96of module14when cover96is mounted to main housing94. Cable exits120define a protruding rear lip122that is slidably inserted into slots124defined around front apertures126for accommodating cable exits120. Cover96also includes slits128that receive rear lips122of the cable exits120to capture cable exits120. Cable exits120permit telecommunications cables within module14to be directed outside of module14. Cable exits120are preferably sized thin enough to fit within the profile of the fiber optic splitter module14, as shown inFIG.25, to preserve the density of the telecommunications assembly10.

Main housing94includes an integrally formed flexible latch52(i.e., cantilever arm) that is adapted to engage a portion of chassis12to hold module14within front opening30of chassis12. Flexible latch52also deflects to permit withdrawal of module14from chassis12.

Still referring toFIGS.20-30, latch52of module14includes a finger grip tab130, a front latching tab132and a rear latching tab134. Front latching tab132and rear latching tab134define a recess136thereinbetween. Rear latching tab134includes a ramped face138that causes latch52to elastically deflect down when module14is being inserted into chassis12. Rear latching tab134also includes a square face140that opposes a square face142of front latching tab132.

Front lip50of bulkhead48at mounting location38of chassis12is captured in recess136between the two latching tabs132,134to hold module14in place within chassis12. During insertion, as front lip50of bulkhead48clears ramped rear tab134and is captured in recess136between the two latching tabs132,134, latch52flexes back upwardly. Recess136between the two tabs132,134of latch52allows for a certain amount of horizontal float for splitter module14within chassis12, as will be discussed in further detail below.

The removal of module14from chassis12is performed by pressing latch52downwardly to clear the square face140of rear tab134from lip50and sliding module14away from chassis12. Module14includes a fixed grip tab144opposing and adjacent to flexible latch52to aid removal of module14from chassis12. Fixed grip tab144is formed as a part of front wall106of module14. Fixed grip tab144is preferably positioned on module14opposite latch52so that a user may apply opposing force on latch52and fixed grip tab144to securely grasp module14and remove it from chassis12. Fixed grip tab144is preferably positioned on module14close enough to latch52so that a user may be apply the force with two adjacent fingers of the hand.

FIG.22shows an exploded view of fiber optic splitter module14illustrating the internal components of module14. Fiber optic splitter module14is shown inFIG.22with adapter assembly16exploded from module14.

Within interior114of main housing94, splitter module14includes a first radius limiter146adjacent curved portion122of rear wall104of main housing94. Splitter module14includes a second radius limiter148adjacent front wall106of housing94near cable exits120. Connectors118of splitter module14are slidably inserted into opposing slots154formed in apertures156at the rear wall104. Connectors118project out from rear wall104at inset portion116of rear wall104. Outer housings150of connectors118include transverse flanges152that are received within the opposing slots154formed in apertures156that accommodate the connectors118. Once slidably inserted, connectors118are captured within housing92by cover96.

Adjacent bottom wall102of main housing94within interior114is an optical component158such as a fiber optic splitter or a fan-out. Optical component158is held against the interior of bottom wall102by a clamp160(i.e., bracket). Clamp160is mounted to a clamp mount162defined on splitter module main housing94with fasteners (not shown). In the embodiment of the housing94shown in the FIGS., clamp mount162includes two pairs of mounting holes164,166. Either the upper set of holes164or the lower set of holes166are utilized depending upon the size of the clamp that will be used to hold optical component158against bottom wall102. It should be noted that different optical components may have different thicknesses and may require the use of different sized clamps for holding the optical components in place. In certain embodiments, two optical components that are stacked on top of another may be used, in which case, a smaller clamp would be used to hold the two optical components in place.

Optical component158is offset from the interior side of first transverse sidewall98by a set of cable management structures168. In the embodiment of the module14illustrated, the set of cable management structures168are elongate structures170defining cable management slits172therein between. When optical component158is held in place, cables can be routed through slits172between optical component158and the interior of first transverse wall98(please seeFIGS.29and30).

Splitter module main housing94also includes integrally formed crimp holders174(e.g., slots) adjacent front wall106of housing94underneath second radius limiter148. Crimp elements176crimped to the ends of cables that are split by optical component158are slidably received into crimp holders174as shown inFIGS.22and29. Crimp elements176define square flanges175between which is defined a recessed portion177. The crimp holders174include complementary structure to the crimp elements such that once the crimp elements176are slidably inserted into the crimp holders174, the crimp elements176are prevented from moving in a longitudinal direction due to the flanges175. Once slidably inserted, crimp elements176are held in place by cover96that is mounted to splitter module main housing94. In the embodiment shown, there are nine crimp holding slots174, each one being able to accommodate up to four crimp elements176. Other numbers are possible. Other complementary shapes between the crimp elements and the crimp holding slots are also possible to provide a slidable fit and to prevent axial movement of the crimp elements once inserted therein the crimp holders.

FIG.29shows fiber optic splitter module14without a cover96exposing the interior features of fiber optic splitter module14including routing of a fiber optic cable within fiber optic splitter module14.FIG.30illustrates a cross-sectional view taken along section line30-30ofFIG.29.

As shown inFIG.29, a first cable178extends from connector118toward optical component158, mounted within module housing92. Optical component158, as previously discussed, may be a splitter or a fan-out or another type of optical component. In the embodiment shown, optical component158is a fiber optic splitter that splits the signal of a single strand to a plurality of secondary signals. In another embodiment, first cable178may be a multi-strand fiber cable with a plurality of strands of optical fiber and optical component may be a fanout to separate the individual strands into each of a plurality of second cables.

First cable178, as it extends toward optical component158, is inserted through slits172(seeFIGS.22,29, and30) located between optical component158and the inner side of first transverse sidewall98of module housing94and looped around first radius limiter146and then around second radius limiter148before being received by optical component158. Second cables180extend from optical component158and are looped again all the way around first radius limiter146before heading toward crimp holders174. From crimp holders174, cables (not shown) crimped to the other ends of the crimps176exit the module through module exits120.

An outside cable (not shown) may extend to rear end70of an adapter64of adapter assembly16and be terminated by a connector (not shown inFIG.29) that is optically connected to connector118of module14through adapter64once module14is inserted within chassis12. It should be noted that the routing of the fiber optic cables within module14as shown inFIGS.29and30is only one example and other ways of routing the cables within the module are possible.

The embodiment of the fiber optic splitter module14shown in the FIGS. is configured such that it can accommodate reduced bend radius fiber. A reduced bend-radius fiber may have a bend radius of about 15 mm whereas a non-reduced bend-radius fiber may have a bend radius of about 30 mm.

Similar fiber optic splitter modules are described in commonly-owned U.S. Pat. Nos. 7,376,322; 7,400,813; 7,376,323; and 7,346,254, the disclosures of which are incorporated herein by reference.

The insertion of a splitter module14into chassis12is illustrated inFIGS.31-35. Referring toFIGS.31-35, insertion of fiber optic module12into front opening30of chassis12begins the mating of module14to chassis12and to adapters64of adapter assembly16. Top flanges engage44top slots40and bottom flanges46engages bottom slots42of chassis12as module14is inserted.

Still referring toFIGS.31-35, chassis12includes a flexible shield182in each mounting location38. Shield182is adapted to prevent protection against accidental exposure to light. Shield182is positioned in front end68of each adapter64of adapter assembly16. Before a splitter module14is placed in an associated mounting location38, if a connectorized cable that is connected to an adapter64of adapter assembly16is illuminated and transmitting light signals, shield182will prevent accidental exposure to these signals which might damage eyes or other sensitive organs, or nearby communications equipment. The insertion of splitter module14pushes shield182out of the way as illustrated inFIGS.31-33.

Shield182is deflected by module14as module14is inserted through front opening30so that connectors118of module14can mate with adapters64of adapter assemblies16. Shield182is preferably made of a resilient deformable material that will return to the position when module14is withdrawn from mounting location38.

For example, inFIG.31, a fiber optic splitter module14is shown partially inserted within chassis12prior to connectors118of splitter module14having contacted shield182of chassis12. InFIG.32, fiber optic splitter module14is shown in a position within chassis12with connectors118of fiber optic splitter module14making initial contact with shield182of chassis12to move shield182out of the way (a side cross-sectional view is shown inFIG.34). InFIG.33, fiber optic splitter module14is shown in a fully inserted position within chassis12, having moved shield182out of the way (a side cross-sectional view is shown inFIG.35).

Shield182is configured such that shield182does not engage the ferrule184of connector118of splitter module14when connector118contacts shield182to move it out of the way. Instead, outer connector housing150pushes shield182out of the way.

Shield182may be connected to chassis12by fasteners, or, alternatively, shield182may be formed integrally with chassis12or mounted by spot—welding or other fastening techniques.

As shield182is fully deflected, further insertion of module14brings connectors118into contact with adapters64and connectors118are received within front ends68of adapters64. Latch52is deflected inwardly as module14is inserted and then flexes back so that front lip50of bulkhead48is captured in recess136. Module14is now in position to process and transmit signals from cable through first cable178, optical component158and second cable180within module interior114.

Referring toFIG.35, as noted above, recess136between the two tabs132,134of latch52provides a certain amount of horizontal float for the splitter module14within chassis12. Front lip50of bulkhead48is allowed to move a distance of D as indicated inFIG.35before it makes contact with square face140of rear tab134. Splitter module14is configured such that, when splitter module14is pulled away from front32of chassis12, distance D front lip50of bulkhead48travels before contacting square face140of rear tab134is less than the horizontal float (i.e., distance A) provided for adapter assembly16, as discussed before.

In this manner, splitter module14provides a form of protection from accidentally disengaging connectors118of the module from adapter assemblies16at rear28of chassis12. The size of recess136of module14is configured such that the horizontal float of splitter module14is interrupted before the adapter assembly16can be pulled far enough toward the front of chassis12to stop its horizontal movement and accidentally disengage connectors118of module14from adapters64.

FIGS.36-45illustrate a dust cap/test tool190configured for use with adapter assembly16of telecommunications assembly10. Dust cap/test tool190includes a body192with a front end194and a rear end196. Dust cap/test tool190includes a pair of connectors118protruding out from front end194. As shown inFIG.39, the pair of connectors118are slidably inserted into connector holders193of the body192of dust cap/test tool190. Connector holders193include slots195for receiving flanges of outer housings of connectors118, as in housing94of splitter module14. Dust cap/test tool190also includes a pair of dust plugs198protruding out from rear end196. Dust cap/test tool190includes a top wall200and a bottom wall202and a first transverse side204and a second transverse side206. The top and the bottom walls200,202include top and bottom flanges208,210, respectively, for slidable insertion into chassis12similar to fiber optic splitter module14. First transverse side204includes a radius limiter212for guiding cables terminated to connectors118of dust cap/test tool190. There is a first grip214integrally formed with body192at front end194. There is a second grip216defined at the end of the radius limiter212integrally formed with body192at rear end196of dust cap/test tool190.

As shown inFIGS.36and37, dust cap/test tool190is slidably insertable within chassis12and usable in two different ways. InFIG.36, dust cap/test tool190is shown being used as a test tool to test the optical signals input into the adapter assemblies16. Since adapter assemblies16are located at rear end28of chassis12and front ends68of adapters64of adapter assemblies16are located in the interior of chassis12at rear28, it becomes difficult to access to the connections for testing or other purposes. The pair of connectors118on front end194of dust cap/test tool190are designed to be coupled to adapters64of adapter assembly16when dust cap/test tool190is slidably inserted into chassis12. In this manner, the connections at adapter assemblies16can be tested without having to uncouple adapter assemblies16from chassis12and without having to reach into chassis12.

As shown inFIG.37, dust cap/test tool190can also be flipped around 180° and used as a dust cap to seal the interior of adapters64from contaminants. If a splitter module14is not inserted within one of the mounting locations38of chassis12, dust cap/test tool190can act as a placeholder and be slidably inserted within chassis12. The dust plugs198include recessed portions199for receiving protruding tabs89of arms91of housing halves at the interior of an adapter64. The recessed portions199help retain the dust plugs198within the adapters64.

InFIG.38, dust cap/test tool190is shown in combination with an adapter assembly16exploded off. InFIG.39, dust cap/test tool190is shown with an adapter assembly16mounted thereon and shown with one of the testing connectors118of dust cap/test tool190exploded off dust cap/test tool190.

FIGS.46-52illustrate a grip extension218adapted for use with connectors118coupled to rear70of adapters64of adapter assembly16. Grip extension218is designed to add length to the outer housing150of a connector118to facilitate access to individual connectors118in dense environments such as the telecommunications assembly10. Grip extension is preferably first mounted over a cable before the cable is terminated to a connector118. Once the connector118is terminated to the cable, grip extension218is slid over the boot portion220of the connector and mounted to the outer housing150of connector118as shown inFIG.7.

Referring toFIGS.46-52, grip extension218includes an elongate body222with four cantilever arms extending from a front portion224of the body222. Two of the opposing cantilever arms226,228include protruding tabs230for engagement with the gripping surface232of outer housing150of connectors118. Two of the other opposing cantilever arms234,236include slits238for engaging the flanges240defined on connector outer housings150. With the four cantilever arms226,228,234,236, the grip extensions218are snap-fit onto connector housings150. The rear portion242of the grip extension body222includes a top side244, an open bottom side246and two transverse sides248,250that taper in going in a direction from the front224to the back242. Top and bottom sides244,246include grip structures252to facilitate pulling on grip extensions218to remove connectors118.

The above specification, examples and data provide a complete description of the manufacture and use 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.