Optical waveguides – Accessories – External retainer/clamp
Reexamination Certificate
2002-01-02
2004-03-02
Patel, Tulsidas (Department: 2839)
Optical waveguides
Accessories
External retainer/clamp
Reexamination Certificate
active
06701056
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention relates to optical components and systems, and more particularly, to a modular, variably configurable retainer assembly for optical components.
Discrete optical components, such as couplers, isolators, combiners and wavelength division multiplexers (“WDMs”) are often interconnected to create optical circuits used to create a variety of functionalities provided by optical modules including multiplexers, demultiplexers, interleavers, deinterleavers, splitter arrays and the like. Optical fibers are typically utilized to provide the multiple optical paths among such components in the optical module. A number of mass fusion splices (that may include relatively high fiber counts) may also be necessary to implement the optical circuit which may include dozens of separate optical pathways. An optical module is typically embodied in a package that organizes and locates the optical components in an appropriate spatial relationship to effectuate the optical circuit while simultaneously affording physical protection to the optical components, fibers and splices. Such packages include various holders, trays or retainers that are populated with the optical components and mass fusion splices during the manufacturing buildup of the optical module. Typically, the holders, retainers, and trays (collectively referred to simply as “holders”) are then subsequently placed in an enclosure that houses and provides the exterior surfaces of the optical module. Optical cables or ribbons (i.e., pigtails) that may include connectors typically terminate the primary optical fibers and are then run outside the enclosure to provide access to the internal optical pathways.
Holders for optical components and splices in the prior art include those employing (alone or in various combinations) mechanical, adhesive, and magnetic retention solutions. Mechanical solutions include, for example, resilient foam to surround the optical components and splices, and press-fit and loose-fitting arrangements employing plastic retainers. Adhesives, such as glue and epoxy, have also been used to bond optical components and splices to the holder in the desired configuration. Optical components and splices may also be located in a holder using magnetic strips that are respectively affixed to the elements and holder. Some holder arrangements in the prior art, such as trays, require the use of a separate cover element to fully implement the required retention and/or protection of the optical components and splices.
Unfortunately, few prior art holders have proven to be entirely satisfactory. Disadvantages associated with such prior art holders include lack of precision in locating optical components and splices (foam, loose-fit), reduced physical protection (foam, loose fit), and reduced manufacturing flexibility in building up the optical module (adhesive), organizing the optical components and splices therein (adhesive), or configuring the holders themselves (all prior art solutions). Some holders in the prior art, for example, the adhesive and magnetic arrangements (and those requiring covers) also add undesirable extra manufacturing complexity, duration, and expense.
SUMMARY OF THE INVENTION
A variably configurable and modular retainer for various discrete optical components (such as passive optical elements and mass fusion splices) is provided by a substantially planar base having an optical component support surface. Complementary finger pairs extend upwardly from the base. Each finger is disposed in an opposing arrangement with the other finger in the finger pair and is provided with an inner and outer surface. The respective opposing inner surfaces (each having a slightly concave profile) define an optical component receiving area that is sized and shaped to accommodate an optical component or splice. Each finger pair is resilient and laterally biased with a normal bias such that the inner surfaces are urged laterally inwardly and being moveably outwardly for interlockingly engaging an optical component using a snap-fit. The optical component may be thereby retained substantially against the support surface of the base.
In an embodiment of the invention, side structures are disposed adjacent to the base that include one or more connective elements that form a selectively engagable interconnection with a complementary connective element on an adjacent retainer in a modular retainer assembly. The invention thus provides a modular retainer assembly (comprising a plurality of modular retainers) that may be arranged in a variably configurable planar array.
One portion of the connective element may comprise a male side structure including an resilient interlocking tab extending laterally from the male side structure. The other portion of the connective element may comprise an opposing female side structure that includes a mating slot arranged to mate with an interlocking tab of an adjacent retainer. A matching lug and recess, disposed respectively in the adjoining connective slot and tab, may be used to provide vertical registration of the side structures of the adjacent modular retainers to ensure substantial co-planarity of the assembled planar array. The interlocking tab and slot are slidably engaged along a vertical plane until the lug fits into the recess to thereby provide a snap-fit registration.
In another embodiment of the invention, the modular retainer assembly further includes an interconnector having first and second members each having complementary-shaped facing portions therewith. The first member is resilient and projects downward from the base. The second member is disposed on the base or side structures of the modular retainer. The complementary members thereby form a selectively engagable interconnection with an adjacent stacked modular retainer. The invention thus provides a stackable modular retainer that facilitates the assembly of the modular retainers into variably configurable columnar arrays.
The interconnector members may comprise a complementary hook and catch. The hook projects from the bottom of the retainer base with the opening of the hook projecting laterally inward with a normally inward bias. The catch is disposed on a top surface of the retainer with a lateral outward projection so as to receive the hook from a stacked modular retainer. The hook and catch are slidably engaged along a vertical plane as the adjacent modular retainer is placed to form the columnar stack. The hook deflects outwardly during the slidable engagement until it deflects past the lateral projection of the catch to thereby hold the catch in a snap-fit engagement.
The complementary finger pairs may be shaped to retain optical components with a substantially cylindrical cross sections or may be shaped to retain elements having an oval cross section such as mass fusion splices. The complementary finger pairs are arranged in a substantially rectangular and uniform grid having multiple rows and columns (in plan view) to thereby accommodate the retention of a plurality of optical components or splices in a spatial orientation that facilitates the interconnection of those elements to form an optical circuit. The placement of optical components and splices within the rows and columns of finger pairs may thus be variably configured according to the specific optical circuit being implemented, and additional retainers may be added in planar or columnar fashion to create a modular retainer matrix to implement other retention configurations as required by the application.
In various aspects of the invention, an injection-molded thermoplastic resin (such as polycarbonate) is used to form the modular retainer as a single unitary (i.e., monolithic) body. Optical fiber pathways may be molded into the top surface of the base to provide spaces within the modular retainer to accommodate the connective optical fibers used in an optical circuit. Modular retainers may be arranged to accommodate solely optical components (where the optical components are relatively small and consequently more may be ac
Burek Denis Edward
Mock George Edwin
Mayer Fortkort & Williams PC
Mayer, Esq. Stuart H.
Patel Tulsidas
Wavesplitter Technologies, Inc.
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