Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application is a continuation of U.S. patent application Ser. No. 10/651,565, filed on Aug. 29, 2003 now U.S. Pat. No. 6,821,031, which is a continuation of U.S. patent application Ser. No. 09/871,836, filed on Jun. 1, 2001 now U.S. Pat. No. 6,637,949, which applications are incorporated herein by reference. 

   TECHNICAL FIELD  
   The present invention relates to fiber optics used for signal transfer. More particularly, the present invention is based on multi-directional fiber optic connections for devices with fiber optic inputs and/or outputs. 
   BACKGROUND  
   Fiber optic cables are useful for signal transfer. Light pulses representing data travel through the cables over very long distances and with great immunity to noise and other interference. However, fiber optic cables are more fragile than cables having electrical conductors. The fibers in the cable can be broken if the cable is bent beyond a certain amount. Once fibers are broken, signal transmission that is dependent upon those fibers terminates. Also, signal transfer in optical fibers is more susceptible to attenuation caused by bends in the fiber than is signal transfer through wires. 
   Typically, broken fibers and attenuation are not a problem in the median regions of the fiber optic cables. However, fiber at the ends of the cables can be troublesome because the cable must often bend where the connector attaches to a device. This is especially true when in confined spaces, such as when the device is mounted in a wall and the fiber connections to the device are made within the wall. 
   Ordinarily in walls, the fiber optic cable is routed parallel to the plane of the wall and within a gap separating panes of the wall. The fiber connections on the device are oriented perpendicular to the plane of the wall. Therefore, the cable must bend to account for the right angle between the direction of the fiber connector and the direction the cable is routed. If this bend forms a radius less than the minimum bend radius for the cable, a fiber break can result or the signal may become too attenuated for proper communication. For relatively narrowly gapped walls, a fiber break or attenuation is more likely to occur because the cable must form a bend with a relatively smaller radius. 
   SUMMARY  
   The present invention addresses these and other problems by providing multi-directional fiber connections. The fiber connections on the device are movable in relation to the housing so that the fiber optic cables can interface with the fiber connections on the device while forming a greater bend radius than would result had fixed fiber connections been used. The greater bend radius reduces the likelihood of broken fibers or signal attenuation. 
   The present invention is embodied in a device for coupling a first signal line to a fiber optic cable. The device includes a main housing and also includes at least one connector receptacle that is movably supported by the main housing. The connector receptacle is for interfacing with the fiber optic cable. 
   The present invention is also embodied in a method for providing a device that couples a first signal line to a fiber optic cable. The method involves providing a main housing having a connector receptacle mount and providing a connector receptacle that is configured to movably attach to the connector receptacle mount and receive the fiber optic cable. The method also involves movably affixing the connector receptacle to the main housing by attaching the connector receptacle to the connector receptacle mount. 
   Another device embodying the present invention includes a main housing. The device also includes means for movably supporting a connector receptacle within the main housing. The connector receptacle interfaces with a fiber optic cable and transfers the signal being carried by the fiber optic cable. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is a front perspective view of one device embodying the present invention and having a jack for transferring electrical signals and having two fiber optic connector receptacles for transferring light pulses. 
       FIG. 2  is a rear perspective view of the device further illustrating the connector receptacles. 
       FIG. 3  is an exploded perspective view of the device. 
       FIG. 4  is a top view of an alternative embodiment of the device with the top hull removed. 
       FIG. 5  is a top view of the device. 
       FIG. 6  is a front view of the device. 
       FIG. 7  is a perspective view of the electrical components of the device. 
       FIG. 8  is a top view of the electrical components of the device. 
       FIG. 9  is a front view of the components of the device. 
       FIG. 10  is a right side view of the components of the device. 
       FIG. 11  is a right side view of the two devices as they would typically be situated when mounted within a wall. 
       FIG. 12  is a perspective view of two exemplary devices as they would typically be situated when mounted within a wall. 
       FIG. 13  is a top view of another embodiment of the present invention having orbital fiber connections. 
       FIG. 14  is a side view of the embodiment with orbital fiber connections. 
       FIG. 15  is an exploded perspective view of the embodiment with orbital connections. 
   

   DETAILED DESCRIPTION  
   Various embodiments of the present invention will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to various embodiments does not limit the scope of the invention, which is limited only by the scope of the claims attached hereto. 
   The present invention provides multi-directional connections for fiber optic cable to devices with fiber optic inputs and/or outputs referred to as connector receptacles. The multi-directional connections can take various forms including pivotal connections, as shown in  FIGS. 1–12 , that limit the connection&#39;s movement to rotation about one axis. Other multi-directional connections are possible as well such as orbital type connections as shown in  FIGS. 13–15  allowing movement of the connections in a virtually unlimited number of axes. 
   Devices utilizing the present invention allow the connections to be oriented in a direction that more closely aligns the connector receptacle with the direction of travel of the fiber optic cable. This alignment allows the fiber optic cable to interface with the device with a relatively large bend radius or no bend at all. Maximizing the bend radius reduces the likelihood that fiber breaks will occur or that the light pulse signal will be too greatly attenuated for proper signal transfer. 
     FIGS. 1 and 2  are front and rear perspective views and  FIGS. 5 and 6  are top and front views of one embodiment of the present invention. The device  100  in this embodiment is a media converter that receives a signal in one media and outputs the signal in another media. As shown, the media converter  100  is setup to establish two-way communication using two fiber optic cables, one for transmitting and one for receiving, and a single RJ-45 jack supporting bi-directional communication. The media converter  100  receives light signals through one fiber optic receptacle  106  that interfaces with a fiber optic cable (not shown) that carries the received light signal. The media converter  100  outputs an electrical signal corresponding to the light signal through an RJ-45 jack  116  which has a plurality of electrically conductive pins  116 ′. 
   In the embodiment shown, the media converter also receives electrical signals through the RJ-45 jack  116  and converts the electrical signal to light signals that are output through connector receptacle  108 . Another fiber optic cable (not shown) interfaces with connector receptacle  108  and carries the light signal being transmitted by the media converter  100 . Other devices in addition to media converters may utilize the present invention, and the number and types of connector receptacles and jacks employed by the device may vary from those shown. 
   The device  100  in this embodiment has a main housing  101  consisting of two joined hulls  102  and  104 . The hulls  102 ,  104  are held together by assembly connections  120  formed by tabs and nubs. The hulls  102 ,  104  provide mounting catches  114  that hold the device in place when mounted in a wall frame. The hulls  102 ,  104  form a semi-cylindrical end  118  where the connector receptacles  106  and  108  are located. The connector receptacles  106 ,  108  of this embodiment are unified by a second housing  110  that is cylindrical. The second housing  110  fits within the semi-cylindrical end of the main housing  101  formed by hulls  102  and  104 . 
   The second housing  110  provides end shafts  112  that protrude through holes  113  in the semi-cylindrical end of the device  100 . The end shafts  112  secure the second housing  110  within the main housing  101  but allow the second housing  110  to rotate about the axis formed by the end shafts  112 . The second housing  110  supports the connector receptacles  106  and  108 . The semi-cylindrical end  118  of the main housing  101  is provided with slots  122  and  124  from which the connector receptacles  106  and  108  protrude. Because the second housing  110  is able to rotate and the slots are provided in the main housing, the connector receptacles  106  and  108  are able to pivot about the axis formed by the endshafts  112 . Some friction results from the endshafts  112  located within the holes  113 , and this friction holds the receptacles  106  and  108  in a given position when they are not otherwise being pivoted. 
   An exploded view of the embodiment shown in  FIG. 1  is shown in  FIG. 3 . The top hull  102  of the device  100  has mounting tabs  114  that allow the device to be inserted into a wall mount and fixed in place. The top hull  102  also has housing assembly tabs  134  for securing the top hull  102  to the bottom hull  104 . The top hull  102  also is provided with a quarter cylindrical end  119  with a semi-circular hole  113 ′ that supports the endshafts  112  of the second housing  110  along with a semi-circular hole  113 ″ in the bottom hull  104 . 
   The bottom hull  104  similarly has mounting tabs  114  for mounting the device to a wall mount. The bottom hull  104  also provides nubs  136  that provide a catch for the assembly tabs  134  located on the top hull  102 . The top hull  102  and bottom hull  104  are secured together by the assembly tabs  134  and nubs  136 . The media converter components of the exemplary embodiment are housed within the main housing  101  created by the attachment of the top hull  102  and the bottom hull  104 . The bottom hull  104  also provides a quarter cylindrical end  117  that forms a semi-cylindrical end  118  when mated with the quarter cylindrical end  119  of the top hull  102 . Slots  138  and  140  are also provided in the bottom hull  104  and are aligned with slots  122 ,  124  of the top hull  102  to permit connector receptacle movement relative to the main housing  101  formed by the joined top and bottom hulls  102  and  104 . 
   The media converter components within the main housing  101  include a circuit board  132  supporting jack  116 . A circuit board  130  is also included and supports transformers  124 ,  126  and an integrated circuit chip  128 . These components are discussed in more detail below with reference to  FIGS. 7–10 . 
     FIG. 4  shows a perspective view of an embodiment utilizing a transformer configuration different than that of the embodiment of  FIGS. 1–3 . The top hull  102  has been removed so that the fit of the components within the bottom hull  104  can be seen. In this embodiment, the transformers  124 ′ and  126 ′ are mounted side-by-side with their longitudinal direction extending side-to-side rather than front-to-back. The transformers  124 ′ and  126 ′ are mounted to a circuit board  130 ′ having a space  128 ′ for mounting the integrated circuit chip  128 . The circuit board  130 ′ mounts to a circuit board  133  supporting the jack  116 . The circuit board  133  is supported by the bottom hull  104  that also supports the second housing  110  with receptacles  106 ,  108 . 
   The media converter components, partially shown in  FIGS. 7–10 , are well known in the art and include the RJ-45 jack  116  mounted to a circuit board  132 . Also included in the standard media converter components are the integrated circuit  128  and transformers  124  and  126 . As shown, the integrated circuit  128  and transformers  124  and  126  are mounted on circuit board  130  that is connected to circuit board  132  by header connector  131 . The circuit board  132  permits transfer of electrical signals from the RJ-45 jack  116  to circuit board  130  and from circuit board  130  to a flex circuit  142  that electrically communicates with receptacle circuit board  123 . Receptacle circuit board  123  supports converter circuitry (not shown) that communicates with the integrated circuit  128  through the flex circuit  142 . The converter circuitry (not shown) and receptacle board  123  are mounted within the second housing  110 . 
   The converter circuitry (not shown) supported by the receptacle circuit board  123  and housed by the second housing  110  has a photodetector fixed relative to the connector receptacle  106  for receiving light that has transferred from the fiber optic cable that is connected to the connector receptacle  106 . The photodetector converts the light pulses into electrical signals that are passed to the integrated circuit  128  through the flex circuit  142 . The integrated circuit  128  takes the electrical data signals from the photodetector and conditions the signal, as is well known in the art, for transmission through electrical wires that contact the pins  116 ′ of the RJ-45 jack  116 . 
   The converter circuitry supported by the receptacle circuit board  123  and housed by the second housing  110  also has a light emitter fixed relative to the connector receptacle  108 . The emitter is for applying light pulses to the fiber optic cable interfaced with the connector receptacle  108 . The emitter converts electrical signals that were passed through the RJ-45 jack  116  and conditioned by the integrated circuit  128  into the light pulse signals that can be transmitted by the fiber optic cable. The emitter receives the electrical signal through the flex circuit  142 . 
   As is known in the art, the flex circuit  142  is a flexible piece of material that has individual, isolated conductors passing through it. The flex circuit  142  allows the emitter and the photodetector to remain in electrical communication with the circuit board  130  even though the emitter and photodetector move in relation to the circuit board  130  when the connector receptacles  106  and  108  move in relation to the main housing  101 . In this embodiment, the flex circuit  142  allows the bend in the signal transfer media to occur in wires of the flex circuit  142  rather than in the fiber. Wires generally are not damaged by a relatively small bend radius, and electrical signal attenuation does not occur in wire bends. Therefore, signal transfer is unaffected by the movement of the connector receptacles  106  and  108  in relation to the main housing  101 . 
   Although the embodiment shown illustrates a main housing  101  supporting the connector receptacles  106 ,  108  such that they may pivot, the connector receptacles  106 ,  108  may be movably supported in other ways. For example, the connector receptacles may be orbitally supported by the main housing  101  as shown in  FIGS. 13–15  and discussed below. Furthermore, the connector receptacles may vary in number for a given device and may be independently movable with respect to one another. For instance, each connector receptacle may have its own independent orbital support. 
   Also, the connector receptacles may movably attach to the main housing directly, rather than through the secondary housing. The main housing may provide connector receptacle mounts other than a second housing. For example, the connector receptacles could mount to the main housing with pins that rotate within mounting holes provided by the main housing. Other methods for mounting the connector receptacles to the main housing without using secondary housings are possible as well. 
   The range of movement of the connector receptacles can be restricted if necessary. Limiting the size of the slot that the connector receptacle protrudes from is one way to provide such a restriction. An example of where a limited range of movement is desirable is where the opening in the secondary housing that allows the flex circuit to pass through can be partially exposed to the outside by the slot for the connector receptacle&#39;s protrusion. If a restriction is not imposed and the connector receptacle is moved to an extreme position, such exposure may occur. Therefore, it may be desirable to prevent the opening for the flex circuit to be exposed to prevent debris from entering the second housing and/or the main housing. 
     FIG. 11  shows a side view and  FIG. 12  shows a perspective view of two media converter units  200 ,  202  being positioned in a wall mount configuration. The units  200  and  202  are horizontally mounted and the ends opposite the fiber optic cable connectors  204 ,  206  typically mount flush with the wall&#39;s surface. Often the wall is double paned with a gap between each pane. The units  200  and  202  mount within the gap to remain out of view. 
   Fiber optic cables generally pass between the panes and approach the units  200  and  202  from above or below. The connector receptacles  208  and  210  can be angled toward the approach direction of the fiber optic cables  204 ,  206 . The fiber optic cables  204  and  206  can be aligned with and inserted into the connector receptacles  208  and  210  with a minimum amount of bending. Because the connector receptacles  208  and  210  are directed toward the cable&#39;s direction of travel, the bend radius of the fiber optic cable near the cable connectors  208  and  210  is maximized or eliminated altogether. 
     FIGS. 13–15  show an alternative embodiment of the present invention employing orbital connections to the main housing  300  for each connector receptacle  306 ,  308 . The orbital or ball-and-socket type connections allow the connector receptacles to move in many directions relative to the main housing, and to move independently of one another. Thus, the fiber cable providing a signal to the device may approach from one direction and the fiber cable transmitting a signal from the device may approach from another direction. 
   The housing  300  includes a top hull  302  and a bottom hull  304  attached to one another with assembly connections  320 . The housing  300  includes mounting tabs  314  for fixing the device in place within a wall mount. The bottom hull  304  supports a circuit board  332 . The circuit board  332  supports a jack  316  and a header connector  331 . A circuit board  330  is mounted to the header connector  331  and supports transformers  324 ,  326  and an integrated circuit chip (not shown) that may be mounted in chip area  328 . The circuit board  332  provides electrical connections between the jack  316  and the chip. The circuit board  332  also provides electrical connections between the chip and two flex circuits (not shown). 
   One flex circuit carries electrical signals between the circuit board  332  and a photoelectric circuit board  323 . The photoelectric circuit board  323  is connected to the connector receptacle  308 . The other flex circuit carries electrical signals between the circuit board  332  and a photoelectric circuit board  325 . The photoelectric circuit board  325  is connected to the connector receptacle  306 . The photoelectric circuit board  323  is mounted within an orb  309  including a top orb hull  310  and a bottom orb hull  310 ′. Likewise, the photoelectric circuit board  325  is mounted within an orb  312  including a top orb hull  311  and a bottom orb hull  311 ′. 
   The orb  309  is supported by the main housing  300 , but the connector receptacle  308  remains movable in many directions due to the semi-circular recess  324  in the top hull  302  and the semi-circular recess  340  in the bottom hull  304  that form a circular hole of the main housing  300  that is slightly smaller in diameter than the orb  309 . Likewise, the orb  312  is supported by the main housing  300 , but the connector receptacle  306  remains movable in many directions due to the semi-circular recess  322  in the top hull  302  and the semi-circular recess  338  in the bottom hull  304 . The circular holes of the main housing  300  are formed on a semi-cylindrical end  318 . 
   The two orbs  309  and  312  are independently movable with respect to the housing  300 . Thus, an input fiber cable (not shown) may approach the main housing  300  from one direction while the output fiber cable-(not shown) may approach the main housing  300  from another direction, and each orb  309 ,  312  can be moved to point toward the direction from which the corresponding fiber cable approaches. For example, the input fiber cable may approach from above the housing  300  while the output cable approaches from below the housing  300 . Orb  309  can be directed upward while orb  312  is directed downward. Similarly, the input cable may approach from the left while the output cable approaches from the right. Orb  309  can be directed to the left while orb  312  is directed to the right. 
   While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various other changes in the form and details may be made therein without departing from the spirit and scope of the invention.

Technology Category: 3