Optical waveguides – With disengagable mechanical connector – Structure surrounding optical fiber-to-fiber connection
Utility Patent
1998-04-30
2001-01-02
Bovernick, Rodney (Department: 2874)
Optical waveguides
With disengagable mechanical connector
Structure surrounding optical fiber-to-fiber connection
C385S059000
Utility Patent
active
06168317
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates generally to the field of fiber optical connectors and, more particularly, to an adapter and method of making same for ensuring a precise alignment between multi-fiber connectors.
With the demand for high speed, multi-media services constantly increasing, fiber optic technology is gaining increased attention as communication service providers design their networks to carry high bandwidth signals. Fiber optic technology is so attractive because of the tremendous bandwidth capability of light transmission. Light in the visible and near visible spectrum has characteristic frequencies exceeding hundreds of gigahertz (GHz) allowing information transmission at rates unattainable by traditional, twisted-pair wire technology.
In addition to their high bandwidth, optical fibers offer several advantages over copper-based transmission media: fiber optic media have very low loss characteristics, particularly when compared to metallic media. Fiber optic cables are essentially immune to electromagnetic interference and do not generate any electromagnetic fields to interfere with other equipment. Inasmuch as fiber optic cables are nonconducting, they do not load electrical equipment—instead, the cables act as an optoisolator. Furthermore, fiber optic cables are small and lightweight and can be installed where twisted-pair copper wires will not fit. Lastly, optical fiber, despite its significant performance advantage, is price competitive with high-end twisted pair cable.
While these advantages are impressive, fiber optic technology does have its drawbacks. For example, optical fiber connectors are much more complex than copper wire connectors because the fibers must be connected end to end with such precision that the fiber cores align within a few microns, and, in some cases, within a fraction of a micron. The precision required in connecting optical fibers together precludes the practice of bundling large numbers of fibers in a single cable as is frequently practiced with copper wires. Alternatively, fibers are generally organized in a precise, spatial relationship such as in a ribbon cable in which fibers are organized and molded adjacent to one another in a plastic ribbon. The connectors used to interconnect the ribbons to one another are generally made from metal, silicon, or plastic members and have high precision grooves or holes etched therein for receiving the individual fibers. In some instances, fibers are placed alongside one another in a grooved bottom member and a second, complementary top member is placed over the bottom member confining the fibers therebetween. The two member halves are generally secured with clamps and/or an adhesive.
To establish an optical connection, it is critical that the fiber array from one connector precisely align with a fiber array from another connector. While various connector designs have been developed to facilitate fiber alignment, there nevertheless remains room for improvement in the art. Thus, what is sought is an improved alignment mechanism for multi-fiber connectors.
SUMMARY OF THE INVENTION
Certain objects, advantages and novel features of the invention will be set forth in the description that follows and will become apparent to those skilled in the art upon examination of the following or may be learned with the practice of the invention.
The present invention is generally directed to an alignment adapter for use with an optical connector and more particularly to a multi-fiber optical connector. The alignment adapter in a preferred embodiment comprises a substantially planar slab having a central opening for receiving a front end of a connector therethrough. The slab includes a pair of alignment apertures on opposing sides of the central opening that are positioned in a defined spatial relationship with the fibers held in the multi-fiber connector. According to an aspect of the invention, the alignment adapter includes a pair of alignment rods held in the alignment apertures that are used to convert an optical connector into a male type connector. According to another aspect of the present invention, a connector is disclosed having a plurality of channels for holding optical fibers and a pair of alignment apertures positioned adjacent to the fiber holding channels in a defined spatial relationship. When the connector is received through the central opening of the alignment adapter, the alignment apertures of the alignment adapter precisely register with the alignment apertures formed in the connector. As a result, the alignment rods exert virtually no lateral pressure on the connector, which is a frequent problem in certain types of prior art optical connectors. According to still another aspect of the present invention, the connector includes a nose region that is received through the central opening in the alignment adapter and extends the fiber channels forward of the apertures formed in the connector. Advantageously, the fiber ends can be polished at the end face of the connector without causing debris to become lodged in the connector alignment apertures that could result in misalignment.
The precision with which the alignment apertures of the alignment adapter register with the alignment apertures in the connector is a result of the unique method by which these components are manufactured. The process involves etching a monocrystalline material, typically silicon, to form a plurality of parallel fiber grooves and a pair of alignment grooves with the fiber grooves being interposed between the alignment grooves. Those skilled in the art will appreciate that these materials can be etched with a very high degree of precision. Using this etched material as a template, an inverse replica is created that is separated into two parts. One part is used as a pattern for making the alignment adapter members, the other part is used as a pattern for making the connector members. Thus, because both the alignment adapter and the connector are derived from the same precisely etched template, the apertures in the two components align with the same degree of precision.
Because the etched template can be designed to conform precisely to any desired prior art connector standard, an assembly comprising an alignment adapter and connector according to the present invention and configured as a male type connector can be used to couple to similar or prior art connectors with great precision.
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Multifiber-ferrule Ribbon Cable Connector Shrinks Installation Costs, Roger E. Weiss, Lightwave, Oct. 1996.
Bovernick Rodney
Lucent Technologies - Inc.
Stahl Michael J.
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