PATENT DOCUMENT

Publication Number: US-8393802-B2
Application Number: US-89556510-A
Country: US
Kind Code: B2

Title: Cleanable and self-cleaning fiber optic connector

Abstract:
An optical connector having a body with an outer surface, a first cavity extending within the body from the outer surface and a second cavity spaced apart from the first cavity and extending within the body of the connector from the outer surface. An optical component is positioned within the first cavity and an ejector, which extents into the second cavity, is coupled to the optical component. A biasing mechanism is operatively coupled to apply a biasing force to the ejector to secure the optical component within the first cavity. When a force greater than the biasing force is applied to the ejector within the second cavity, the ejector ejects the optical component from the first cavity so that it extends beyond the outer surface.

Claims:
1. An optical connector comprising:
 a body having an outer surface; 
 a first cavity extending within the body from the outer surface; 
 an optical component positioned within the first cavity; 
 an ejector coupled to the optical component; 
 a biasing mechanism operatively coupled to apply a biasing force to the ejector to secure the optical component within the first cavity, wherein when a force is applied to the ejector to overcome the biasing force, the ejector ejects the optical component from the first cavity so that it extends beyond the outer surface. 
 
     
     
       2. The optical connector of  claim 1  wherein the optical component comprises a lens and the optical connector further comprises an optical fiber optically coupled to the lens. 
     
     
       3. The optical connector of  claim 1  wherein the optical component comprises an optical fiber. 
     
     
       4. The optical connector of  claim 1  wherein the ejector comprises a lever and the biasing mechanism comprises a spring positioned between an end wall of the second cavity and the lever. 
     
     
       5. The optical connector of  claim 1  wherein the first cavity includes a cleaning element positioned within a cut-out between the optical component and outer surface and a bore, concentric with the cut-out, that extends from the outer surface through the cut-out. 
     
     
       6. The optical connector of  claim 1  further comprising a second cavity spaced apart from the first cavity, the second cavity extending within the body from the outer surface, wherein the ejector includes a first end that extends into the second cavity and wherein the ejector ejects the optical component from the first cavity when a force greater than the biasing force is applied to the first end of the ejector within the second cavity. 
     
     
       7. An optical jack comprising:
 a body having a front external surface and first and second cavities extending from the first surface into the body; 
 an optical component positioned within the first cavity; and 
 a lever having a first end coupled to the optical component, a second end extending into the second cavity and a pivot point between the first and second ends, wherein the lever is biased to secure the optical component within the first cavity and, wherein when a force is applied to the second end of the lever to overcome the bias, the lever extends at least a portion of the optical component out of the cavity beyond the front surface of the body. 
 
     
     
       8. The optical jack set forth in  claim 7  wherein the optical component comprises a lens and the optical jack further comprises an optical fiber optically coupled to the lens. 
     
     
       9. The optical jack set forth in  claim 7  wherein the optical component comprises an optical fiber. 
     
     
       10. The optical jack set forth in  claim 7  wherein the first and second cavities comprise parallel bores and the cross-section of the first cavity is slightly larger than the cross-section of the optical component. 
     
     
       11. The optical jack set forth in  claim 7  further comprising a cleaning element positioned within the first cavity between the optical component and external surface; wherein the optical component passes through the cleaning element when it is extended out of the cavity by the lever. 
     
     
       12. The optical jack set forth in  claim 11  wherein the cleaning element comprises brush bristles that extend from an interior surface of the first cavity towards a longitudinal central axis. 
     
     
       13. The optical jack set forth in  claim 7  further comprising a retention mechanism adapted to secure a corresponding mated plug connector with a retention force that is greater than a force applied by the spring to bias the lever. 
     
     
       14. The optical jack set forth in  claim 9  wherein the first cavity includes a bore that opens to a larger cavity in which the optical fiber is bent less than a maximum bend radius of the fiber; and wherein when the optical component is extended out of the first cavity the bend in the optical fiber is reduced. 
     
     
       15. An optical jack comprising:
 a body having a front external surface and first and second cavities extending from the first surface into the body; 
 an optical fiber positioned in the first cavity; 
 a lens positioned within the first cavity, the lens optically coupled to the optical fiber; and 
 a lever having a first end coupled to the lens, a second end extending into the second cavity and a pivot point between the first and second ends, wherein the lever is biased by a spring positioned in the second cavity between an end of the second cavity and the second end of the lever to secure the lens within the first cavity and, wherein when a force is applied to the second end of the lever to overcome the bias, the lever extends at least a portion of the lens out of the cavity beyond the front surface of the body. 
 
     
     
       16. The optical jack of  claim 7  wherein the first cavity has a cylindrical bore extending from the first surface of the body to a depth D and wherein the lens and a first end of the optical fiber are positioned within the cylindrical bore such that the first end is spaced apart from the optical fiber by an optical gap. 
     
     
       17. The optical jack of  claim 9  wherein an interior surface of the cylindrical portion in the optical gap is coated with a reflective coating. 
     
     
       18. An electronic device comprising:
 a housing; 
 an electronic component within the housing; and 
 an optical jack communicatively coupled to the electronic component, the optical jack including:
 a body having a front external surface and first and second cavities extending from the first surface into the body; 
 an optical component positioned within the first cavity; and 
 a lever having a first end coupled to the optical component, a second end extending into the second cavity and a pivot point between the first and second ends, wherein the lever is biased to secure the optical component within the first cavity and, wherein when a force is applied to the second end of the lever to overcome the bias, the lever extends at least a portion of the optical component out of the cavity beyond the front surface of the body. 
 
 
     
     
       19. The electronic device of  claim 18  wherein the optical component comprises a lens and the optical jack further comprises an optical fiber optically coupled to the lens. 
     
     
       20. The electronic device of  claim 18  further comprising a cleaning element positioned within the first cavity between the optical component and external surface; wherein the optical component passes through the cleaning element when it is extended out of the cavity by the lever.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates generally to connectors used to transmit optical signals. More specifically, embodiments of the invention pertain to optical connectors that protect optical components of the connector from scratches and other damage. Embodiments of the invention also pertain to electronic devices that include or couple to such optical connectors. 
     A number of different types of optical fiber connectors have been developed. For example,  FIG. 1  is simplified plan view of a Toslink optical connector  2  that is often used in consumer audio equipment to carry a digital audio stream from components such as CD and DVD players to an audio video (AV) receiver that can decode the stream and output it through a set of loud speakers. Connector  2  includes a lens  4  that protrudes from an end of the connector. An optical fiber (not shown) runs through the connector from a cable  6  and terminates at lens  4 . Connector  2  can be coupled to a female receptacle in the AV receiver or other component to enable connection of the fiber within cable  6  to an optical fiber within the AV receiver or other component. When mated, the two connectors align the cores of their respective fibers so that light (and thus the optical signal streams) can pass from the optical fiber in the connector through lens  4  and to the optical fiber in the AV receiver or component. 
     As shown in  FIG. 2 , lens  4  protrudes from the end of connector  2 . The protruding lens is susceptible to being broken or scratched which may result in an undesirable loss of signal. Other optical connector designs place the lens flush with the end of the connector. Such an arrangement also leaves the lens exposed and susceptible to being scratched or broken. 
     In view of the above described deficiencies, new and improved optical connector designs are desirable. 
     BRIEF SUMMARY OF THE INVENTION 
     Embodiments of the invention pertain to optical plug and receptacle connectors that protect the optical components of the connector, such as a lens or an optical fiber, from being scratched or being otherwise damaged. The optical component can be recessed within a cavity of the connector so that it generally not exposed to potential damaging events and operatively coupled to a lever that enables the lens to be pushed out of the cavity so that it can be readily cleaned of dirt and debris. 
     In one particular embodiment, an optical connector having a body with an outer surface, a cavity extending within the body from the outer surface and an optical component positioned within the cavity is provided. An ejector is coupled to the optical component and a biasing mechanism is operatively coupled to apply a biasing force to the ejector to secure the optical component within the cavity. When a force greater than the biasing force is applied to the ejector, the ejector ejects the optical component from the cavity so that it extends beyond the outer surface. The process of ejecting the optical component from the cavity can remove dirt and debris accumulated in the cavity and allows the optical component to be further cleaned. In various embodiments the optical component is a lens and/or an optical fiber. 
     In another embodiment, an optical jack is provided that includes a body having a front external surface and first and second cavities extending from the first surface into the body. An optical component is positioned within the first cavity. The jack further includes a lever having a first end coupled to the optical component, a second end extending into the second cavity and a pivot point between the first and second ends. The lever is biased to secure the optical component within the first cavity. When a force is applied to the second end of the lever to overcome the bias, the lever extends a portion of the optical component out of the cavity beyond the front surface of the body. The process of ejecting the optical component from the cavity can remove dirt and debris that collected in the cavity and allows the optical component to be further cleaned. In various embodiments the optical component is a lens and/or an optical fiber. 
     To better understand the nature and advantages of the present invention, reference should be made to the following description and the accompanying figures. It is to be understood, however, that each of the figures is provided for the purpose of illustration only and is not intended as a definition of the limits of the scope of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a simplified side view of a previously known Toslink optical connector; 
         FIG. 2  is a simplified block diagram of an electronic device  10  and an optical connector system  12 ,  14  according to an embodiment of the present invention; 
         FIG. 3A  is a simplified cross-sectional view of a portion of an optical connector  20  according to one embodiment of the invention; 
         FIG. 3B  is a simplified cross-sectional view of optical connector  20  shown in  FIG. 3A  in which its lens  26  is in an ejected position; 
         FIG. 4  is a simplified cross-sectional view of a portion of an optical connector system  40  according to another embodiment of the invention; 
         FIG. 5  is a simplified cross-sectional view of a portion of an optical connector  70  according to another embodiment of the invention; 
         FIG. 6  is a simplified cross-sectional view of a portion of an optical connector  80  according to still another embodiment of the invention; and 
         FIG. 7  is a simplified cross-sectional view of two optical connectors  90  and  110  according to another embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 2  is a simplified block diagram of an electronic device  10  and an optical connector system according to one embodiment of the present invention. Electronic device  10  includes an optical receptacle connector or jack  12 . Electronic device can be any electronic device that transmits and/or receives optical signals. Examples of suitable devices include handheld media players, cell phones and smart phones, portable or desktop computers or audio video components such as CD players, DVD players, Blue-Ray players, digital video records, AV receivers and the like. 
     As shown in  FIG. 2 , optical receptacle connector  12  can be coupled to an optical plug connector  14  to transmit optical signals between electronic device  10  and another device over a fiber optic cable  16 . Each of connectors  12  and  14  include an optical fiber (not shown) that transmits streams of optical signals. When the connectors are mated together, the cores of their respective fibers are aligned so that the optical signal streams can pass from connector  12  to connector  14  and vice-versa. 
     Embodiments of the invention provide improved optical jack and/or plug connectors  12  and  14 , respectively, that protect optical components of the connector from being scratched or being otherwise damaged in order to reduce the chances of signal loss. In some embodiments an optical component (e.g., lens or optical fiber) of the connector can be recessed within a cavity of the connector so that it is not readily exposed to potential damage if the connector comes into contact with an object that could scratch or otherwise damage the connector. Dirt and debris may collect in such a cavity. Embodiments of the invention operatively couple the optical component to a lever or other type of ejector that enables the component to be pushed out of the cavity so that it can be readily cleaned of any such dirt and debris. 
     In order to better appreciate and understand the present invention, reference is first made to  FIGS. 3A and 3B  which are simplified cross-sectional views of a portion of an optical connector jack  20  according to one embodiment of the invention, which can be incorporated into electronic device  10  as connector jack  12 . Jack  20  includes a lens cavity  22  formed in a body  24  having an exterior surface  25 . Body  24  may be assembled within electronic device  10  such that exterior surface  25  is flush with an exterior surface  18  of the electronic device while the remainder of body  24  is embedded within the electronic device and thus not visible unless device  10  is disassembled. 
     Lens cavity  22  may be a cylindrical cavity or bore in which a lens  26  and an end of an optical fiber  28  are housed. In other embodiments, cavity  22  has a square, rectangular or other cross-sectional shape. In some embodiments, cavity  22  has a cross-section sized to closely match the cross-section of lens  26  so that there is minimal space between lens  26  and the interior sidewall surface of cavity  22 . Lens  26  can be made from a hard material to reduce abrasions or scratches and increase the useful lifetime of connector  20 . In some embodiments, lens  26  is made from hardened glass (e.g., aluminosilcate glass), sapphire, clear ceramics, spinel (e.g., magnesium aluminum oxide) or aluminum oxynitride (e.g., ALON™) 
     Lens  26  is optically coupled to fiber  28  to transmit optical signals between the lens and fiber. In some embodiments, fiber  28  is physically coupled to lens  26 . In other embodiments, and as shown in  FIG. 3A , fiber  28  is spaced apart from the end of lens  26  by a distance, D 1 , that is sufficiently short to allow optical signals to be transmitted between fiber  28  and lens  26 . As a person of skill in the art will appreciate, distance D 1  is dependent on the transmission power of the optical signal stream. Higher power levels allow a larger gap between the lens and the end of the fiber. In some embodiments, D 1  is less than one centimeter. The embodiment shown in  FIG. 3A  improves signal transmission between lens  26  and fiber  28  by coating interior surface  29  of lens cavity  22  with a reflective coating. While not shown in  FIG. 3A , the end of fiber  28  may include a ferrule and be polished smoother to improve the integrity and optical qualities of the fiber. The ferrule may be made out of metal or may be made out of a glass or a ceramic or other material. 
     Connector jack  20  also includes a second cavity  30  into which a first end  32   a  of a lever  32  or other type of ejector extends. In the embodiment shown in  FIGS. 3A and 3B , lever  32  is operatively coupled at or near its second end  32   b  to lens  26  and biased by a spring  34  (or other suitable mechanism) to retract lens  26  within lens cavity  22  so that the lens is positioned a minimum distance (e.g., 2-10 mm) from exterior surface  25 . In other embodiments, instead of being coupled to lens  26 , lever  32  may be coupled to a different optical component, such as fiber  28  or a ferrule or one or more lenses of a multi-lens optical system. 
     When a tool  35  is extended into cavity  30  to overcome the bias of spring  34 , lever  32  pivots around a fulcrum point  33  to extend lens  26  out of cavity  22  as shown in  FIG. 3B . The act of ejecting the lens from cavity  22  pushes dirt and other debris that may have collected within the cavity out. Additionally, any additional dirt or debris that collects on the surface of lens  26  can be removed, for example with a soft brush or a finger tip, to prevent degradation of optical signals transmitted through the lens. In this manner, cavity  22  and lens  26  can be easily be kept clean. Generally, tool  35  and cavity  30  have similar cross-sections (e.g., both may have circular cross-sections or both may have square or rectangular cross-section) so that the tool fits readily into the cavity but this is not necessary for all embodiments. 
     While not shown in  FIG. 3A  or  3 B, connector jack  20  can include one or more active optical components coupled to fiber  28  that convert optical signals received through lens  26  to electric signals that can be processed by electronic device  10  and that convert electric signals generated by electronic device  10  to optic signals that can be transmitted through lens  26  and connector jack  20  to an optical fiber in a corresponding plug connector. Also, as will be understood by a person of skill in the art, connector jack  20  can be mated with a corresponding plug connector so that a fiber with the plug connector aligns with lens  26  to transmit optical signals between the plug connector and fiber  28 . The plug connector can be designed so that it mates with jack  20  when lens  26  is in a recessed position as shown in  FIG. 3A . Alternatively, the plug connector can be designed to include an integrated tool  35  and mate with jack  20  when lens  26  is in an ejected position as shown in  FIG. 3B  in which case the distance D 2  between lens  26  and fiber  28  should be sufficiently small to allow transmission of the optical signal stream between the two components. A variety of different alignment and coupling mechanisms can be used to mate connector jack  20  to the plug connector and such have not been shown in either of  FIG. 3A  or  3 B for ease of illustration. 
       FIG. 4  is a simplified cross-sectional view of a portion of an optical connector system  40  according to another embodiment of the invention having a connector jack  42  and a plug connector  60 . Connector jack  42  includes a cylindrical lens cavity  44  in which a lens  46  and optical fiber  48  are positioned. Jack  42  also includes a second cavity  50  which, along with a cavity  51 , facilitates alignment of corresponding plug connector  60 . A first end of a lever  52  and a spring  54  are situated within cavity  50  in a manner similar to that of lever  32  and spring  34  discussed above with respect to connector jack  20  and  FIGS. 3A and 3B . 
     Plug connector  60  includes an optical fiber  62  that terminates in a cavity  68  positioned between alignment projections  64 ,  66 . Fiber  62  may be polished at its end to improve its optical properties and may also include a ferrule at its end and/or an appropriate lens. Projections  64 ,  66  align with and are inserted into cavities  50 ,  51  of jack  40  when plug connector  60  is mated with jack connector  42 . During a mating event, surfaces  45  and  65  of the connectors may contact each other and projection  66  activates lever  52  to extend lens  46  out of lens cavity  44  towards fiber  62  and into cavity  68 . When the connectors are operatively coupled, lens  46  and fiber  62  are aligned to allow for the transmission of optical signals there between. 
     While not shown in  FIG. 4 , some embodiments of the invention include a mechanical latch or similar mechanism to secure connectors  42  and  60  together once they are mated. For example, in one embodiment, projections  64  and  66  may include notches on the sides of the projections near their distal ends that align with retention mechanisms such as cantilevered springs or detents within cavities  50  and  51 . When the detents and notches can be positioned so that they engage once the connectors are fully mated and provide a force that is sufficient to overcome the force applied by spring  54  that attempts to push the connectors apart. The connectors can then be disengaged when the retention force is overcome by, for example, pulling the connectors apart. In other embodiments, other types of mechanical latches or magnetic latches can be used. 
       FIG. 5  is a simplified cross-sectional view of a portion of an optical connector  70  according to another embodiment of the invention. Connector  70  is similar to connector  40  except that it does not include a lens  46 . Instead, lever  52  is operatively coupled to an optical fiber  72  or, in another embodiment, a ferrule (not shown) coupled to the end of fiber  72 . Spring  54  biases the lever so that a distal end  74  of fiber  72  is within cavity  44  when the connector is not mated to a corresponding male connector. Cylindrical cavity  44  opens into a larger cavity  76 . A portion of fiber  72  is bent within the larger cavity by an amount that is less than the maximum bend radius of the fiber so that the bend does not interfere with the transmission of optical signals along the fiber. When a force is applied to the end of lever  52  that overcomes the bias supplied by spring  54 , lever  52  pivots around fulcrum  53  extending the end of fiber  72  out of cavity  44 , which in turn, reduces the bend of fiber  72  within cavity  76 . Thus, cavity  44  and the end of fiber  72  can be cleaned when an injector tool  35  is inserted in cavity  50  or fiber  72  can be communicatively coupled to another fiber when a corresponding plug connector, similar to connector  60 , is mated with connector jack  70 . 
       FIG. 6  is a simplified cross-sectional view of a portion of an optical connector  80  according to still another embodiment of the invention. Connector  80  is similar to connector  70  except that it includes a fiber/lens cleaning system  82 . In one embodiment, cleaning system  82  includes soft brushes that extend from an interior perimeter wall towards a longitudinal center point of cavity  82 . The brushes help keep dirt and debris out of the lens cavity in the first place. Additionally, each time lever  52  is activated to extend fiber  72  out of its cavity, the fiber passes through brush bristles to remove dirt and debris that may have collected on the end  74  of fiber  72 . In other embodiments, cleaning system  82  includes soft rubber wipes, a diaphragm or similar mechanisms in addition to or instead of brush bristles that brush across and self-clean fiber end  74  as the fiber is extended out of its cavity. 
       FIG. 7  is a simplified cross-sectional view of a portion of an optical connector system that includes mating connectors  90  and  110  according to another embodiment of the invention. Connector  90  includes a body  92  having a lens cavity or central bore  94  and lever cavity  100  formed therein. A lens  96  and optical fiber  98  are situated within lens cavity  94 . Connector  90  also includes a lever  102  that has one end which extends into cavity  100  and a second end coupled to lens  96 . A spring  104  biases the lever so that lens  96  is withdrawn into cavity  100  when the connector is not in use. Connector  110  can be identical to connector  90  and thus includes similar components which are labeled with the same reference numbers for convenience. 
     Each of connectors  90  and  110  includes an engagement projection  108  on the opposite side of the connector as lever cavity  100 . Connectors  90  and  110  can be mated when they are aligned such that engagement projection  108  of connector  90  is positioned opposite lever cavity  100  of connector  110 . When the connectors are so arranged, the engagement projection  108  of connector  110  is correspondingly positioned opposite lever cavity  100  of connector  90 . When the engagement projections are inserted into the respective lever cavities, each activates the lever  102  of the other connector extending lenses  96  towards each other out of cavities  100  and beyond surfaces  95  so that the lenses are communicatively coupled together to allow optical signals to transmit from one lens  96  to the other. In one embodiment, lenses  96  are physically pressed against each other when the connectors are mated. In another embodiment, the lenses are spaced apart by a predetermined distance that is sufficiently small to allow optical signal streams to be passed between the connectors. Some embodiments include mechanical or magnetic retention mechanisms (e.g., notches on projections  108  and detents within cavities  100 ) to secure the connectors together as described above with respect to  FIG. 4 . 
     As will be understood by those skilled in the art, the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. For example, while embodiments of the invention were discussed above with respect to an connector system having a single optical fiber, other embodiments of optical connectors according to the invention may include multiple fibers and multiple corresponding lenses each of which can be positioned within and ejected beyond a respective cavity as described above. Also, some embodiments of connectors according to the present invention may include electrical contacts in addition to optical fibers. 
     As another example, while embodiments of the invention have been described above as having a mechanical lever and spring to eject an optical component from a recessed position, the invention is not limited to any particular ejector system and a variety of other mechanical and/or magnetic ejectors can be employed instead. As one example, in one embodiment end  32   a  of lever  32  extends outside cavity  50  beyond surface  45 . A tool or mating connector can then push end  32   a  flush with surface  45  or within cavity  50  to extend the optical component. As another example, the lever can be made out of a magnetic material and activated to eject the optical component when an opposite polarity magnet (e.g., magnetic tool or a magnetized projection on a mating connector) is inserted into the lever cavity. Additionally, instead of having a lever or other type of ejector that extends a lens or other optical component out of a connector, some embodiments of the invention, the lens is very close to the outer surface of the connector and is covered by a mechanical door. When an insertion tool or projection from a mating connector is inserted into a cavity similar to one of the cavities that houses the lever, the mechanical door is opened to expose the lens thus enabling it to be optically coupled to a lens or optical fiber in a mating connector. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, other equivalents to the specific embodiments of the invention described herein. Such equivalents are intended to be encompassed by the following claims.

Metadata:
Filing Date: 20100930
Publication Date: 20130312
Grant Date: 20130312
Priority Date: 20100930
Inventors: STANLEY CRAIG
GOLKO ALBERT JOHN
ALVAREZ RIVERA FELIX J.
Assignee: APPLE INC
CPC Classifications: [{"code": "G02B6/3866", "inventive": true, "first": true, "tree": "[]"}, {"code": "G02B6/3866", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 45889908