Molded fiber optic ferrule receptable

Optical waveguides – With disengagable mechanical connector – Optical fiber to a nonfiber optical device connector

Reexamination Certificate

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Details

C385S088000

Reexamination Certificate

active

06425696

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates generally to receptacles for fiber optic ferrules, and more particularly, the present invention provides a receptacle having improved alignment and mounting capabilities for a fiber optic ferrule.
BACKGROUND OF THE INVENTION
Referring to
FIG. 1
, illustrated is a sectional view of an optical module
10
configured in accordance with the prior art. The optical module
10
includes a housing
12
having a cylindrical sleeve
11
with a bore
14
. The housing
12
is constructed of metallic material that can be welded or bonded to a semiconductor element
16
. The semiconductor element
16
has an annular flange
18
and electrical leads
20
extending from a base
22
. The semiconductor element
16
is mounted within a socket
24
of the optical module
10
. The semiconductor element
16
is positioned against the inner walls
26
of the socket by spacers
28
. The semiconductor element
16
is secured within the socket
24
by welding or using an adhesive.
The semiconductor element
16
shown in the illustrated embodiment includes a light emitting diode (LED)
30
. In other embodiments the LED
30
can be replaced by a semiconductor laser as a light source. Light waves emitted from the LED
30
are communicated via an optical fiber
32
. An optical ferrule
34
houses and mounts the optical fiber
32
within the bore
14
. An optical fiber terminal
36
positions and mounts the optical fiber cable
38
within the optical ferrule
34
.
The diameter of the bore
14
within the cylindrical sleeve
11
is constant. The optical ferrule
34
is inserted and held within the bore
14
resulting in a tight fit within the bore
14
. As a result of the tight fit between the optical ferrule
34
and the bore
14
, misalignment or physical damage to the optical ferrule
34
and/or the bore
14
sometimes results.
Semiconductor optical transmitters typically have the design as illustrated in FIG.
1
. Performance of an optical semiconductor transmitter is affected by improper alignment of the transmitter lens or LED
30
with then input end
31
of the optical fiber
32
. Proper alignment maximizes the amount of light from the LED
30
to be focused on the input end
31
of the optical fiber
32
. Conventional techniques for improving this alignment include minimizing the space or gap between the optical ferrule
34
and the bore
14
when the optical ferrule
34
is inserted into the bore
14
.
A single-mode optical fiber has a diameter of approximately 10 microns, and the diameter of the bore
14
should match the ferrule
34
diameter on the order of less than several microns in terms of both the tolerance of diameter and circularity. Numerous steps are used in the fabrication process in order to achieve such a high degree of accuracy. Since a conventional housing
12
is made out of metal, very refined mechanical processing is required to fabricate the housing
14
. Moreover, since the diameter of the optical ferrule
34
is typically 2.5 mm, surface roughness must be minimized in order reduce friction and allow insertion or removal of the optical ferrule into or out of the bore in the sleeve.
Accordingly, there is a need for an optical ferrule receptacle providing improved alignment of an optical ferrule, which can be produced at an attractive cost.
OBJECTS AND SUMMARY OF THE INVENTION
An object of the present invention is to provide a receptacle for an optical ferrule having improved alignment capability.
Another object of the present invention is to provide an optical ferrule receptacle that can be produced at a reduced cost.
A further object of the invention is to provide an optical ferrule receptacle constructed out of a single-molded material, such plastic or other polymer.
An additional object of the invention is provide an optical ferrule receptacle having improved socket mounting capabilities for receiving an optical transmitting source.
Another object of the invention is to provide an optical ferrule receptacle having improved capabilities for mounting optical ferrules by minimizing damage to the optical ferrule and optical fibers during the insertion process.
A further object of the invention is to provide an optical ferrule receptacle having increased assembly speed by facilitating the insertion and securing of the optical ferrule within a an optical bore of the optical ferrule receptacle.
Moreover, an object of the present invention is to provide a notch in the housing for a gate where molding material is injected, thereby eliminating the need to remove surrounding excess molding material. The gates are also located in the rear of the receptacle to allow axial flow of molding material during injection molding, thereby producing a symmetric flow around core pins which increases the accuracy of ferrule bore dimensions.
According to the present invention, a fiber optic ferrule receptacle is provided having a single-molded housing having a base, a cylinder on a first side of the base having a bore for receiving an optical ferrule, a socket on a second side of the base opposite the first side, for receiving a ball lens, and the bore having a first diameter at an outer opening distal to the base, and a second diameter at an inner opening adjacent to the base, wherein the first diameter is greater than the second diameter. In a second embodiment of the present invention, a single-molded housing is provided having a base, a cylinder on a first side of the base having a bore for receiving an optic ferrule, a socket on a second side of the base, opposing the first side, for receiving an optical element; and a plurality of sloping ridges located on the inner wall of the cylinder, wherein widths of the sloping ridges increase closer to the base.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1
is a sectional view of an optical ferrule receptacle configured in accordance with the prior art;
FIG. 2
is a perspective view of an optical ferrule receptacle and an adjoining cylinder configured in accordance with the present invention;
FIG. 3
is a side view of the optical ferrule receptacle and cylinder shown in
FIG. 2
, wherein the internal configurations are shown in shadow;
FIG. 4
is an enlarged side view of the optical ferrule receptacle and cylinder shown in
FIG. 3
, wherein the optical ferrule receptacle and cylinder are coupled together;
FIG. 5
is a perspective view of an optical ferrule receptacle configured in accordance with a second embodiment of the present invention;
FIG. 6
is a cross-sectional view of the optical ferrule receptacle shown in and taken along line
6

6
of
FIG. 5
;
FIG. 7
is an end view of the optical ferrule receptacle shown in and taken along line
7

7
of
FIG. 6
; and
FIG. 8
is a perspective view of the optical ferrule receptacle shown in
FIG. 5
, wherein the internal configuration is shown in shadow.


REFERENCES:
patent: 4461537 (1984-07-01), Raymer, II et al.
patent: 5537507 (1996-07-01), Cina et al.
patent: 5661834 (1997-08-01), Watanabe et al.
patent: 6059463 (2000-05-01), Althaus et al.
patent: 6061493 (2000-05-01), Gilliland et al.

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