Fiber optic connector, fiber optic connector and cable assembly, and methods for manufacturing.

(54) Title: FIBER OPTIC CONNECTOR, FIBER OPTIC AND CABLE CONNECTOR ASSEMBLY, AND MANUFACTURING METHODS.

(54) Title: FIBER OPTIC CONNECTOR, FIBER OPTIC CONNECTOR AND CABLE ASSEMBLY, AND METHODS FOR MANUFACTURING.

(57) Summary

A fiber optic connector and cable assembly that includes a fiber optic connector mounted on the end of a fiber optic cable, the fiber optic connector includes a bushing assembly that includes a strand fiber supported within the bushing, the fiber The cable is split by fusion to a fiber optic of the fiber optic cable at a location within the fiber optic connector.

(57) Abstract

A fiber optic cable and connector assembly including a fiber optic connector mounted at the end of a fiber optic cable. The fiber optic connector ineludes a ferrule assembly including a stub fiber supported within a ferrule. The stub fiber is fusion spliced ​​to an optical fiber of the fiber optic cable at a location within the fiber optic connector.

SE ttCKWBÍA 0Ϊ KOWMÍÁ

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Institute

Mexican Property

Industrial

PATENT TITLE NO. 338237

Owner (s): ADC TELECOMMUNICATIONS, INC. &gt;. i_?.

Address: 1050 Westlakes Drive, Berwyn, Pennsylvania '' * 19312, USA

Name: FIBER OPTIC CONNECTOR, FIBER OPTIC CONNECTOR AND CABLE ASSEMBLY, AND MANUFACTURING METHODS.

Classification:

Inventor (s):

lnt.CI.8: G02B6 / 02; G02B6 / 38

MICHAEL JAMES OTT; THOMAS P. HUEGERICH; STEVEN C. ZIMMEL; PONHARITH NHEP

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Twenty Jños &amp; cha de Vencí

The reference patent is

7/2004 and presentation of the title Lo Ir

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signed the Organic nientcl 20 orga with walk¹

D in accordance with the day 23 of the ey of the P or tada from the date

Q in subscribes to this Industrial P piety (Diario Micial de

2I 31/2004, 06/16/2005, 25 in so a), 4 * and 12 'fraction i I and

1/2006, 0 05 / 2009,06 / 01/2010, 18/01 of the Mexican Institute of Industrial Property (DOF 12/27/1999, amended on 10/10/2002, 07/29/2004, 04/08 / 2004 and 09/13/2007); 1, 3 and 5 paragraph a) of the Agreement that delegates powers to the Deputy Directors General. Coordinator, Divisional Directors. Holders of the Regional Offices, Divisional Deputy Directors, Departmental Coordinators and other subordinates of the Mexican Institute of Industrial Property. (DOF 12/15/1999, amended on 02/04/2000, 07/29/2004, 08/04/2004 and 09/13/2007)

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Issue Date: April 8, 2016

DIVISIONAL DIRECTOR OF PATENTS

NAHANNY CANAL REYES

Arenal No. 550, Floor 1.

Santa Mana Tepepan town. Xochimilco, C P. 16020.

Mexico City

Tel. (55) 53 34 07 00 www.impi.gob.inx

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MX / 2016/27142 i

FIBER OPTIC CONNECTOR, FIBER CONNECTOR ASSEMBLY

OPTICAL AND CABLE, AND MANUFACTURING METHODS

CROSS REFERENCE WITH RELATED REQUESTS

This request was filed on February 20, 2013, as a request for

PCT International Patent and claims the priority of US Patent Application Series No. 61 / 600,915, filed on February 20, 2012, US Patent Application Series No. 61 / 661,667, filed on June 19, 2012, Application of US Patent Series No. 61 / 666,683, filed on June 29, 2012 and US Patent Application Series I or No. 61 / 691,621, filed on August 21, 2012, the disclosures of which are incorporated herein by reference in their entirety.

TECHNICAL FIELD

The present disclosure relates generally to fiber optic communication systems. In particular, the present disclosure relates to fiber optic connectors, cable and fiber optic connector assemblies and methods of manufacture.

BACKGROUND

Fiber optic communication systems are becoming predominant in part because service providers want to deliver high-bandwidth communication capabilities (eg, information and voice) to customers. Fiber optic communication systems use a network of fiber optic cables to transmit large volumes of information and voice signals over relatively long distances. Fiber optic connectors are an important part of most fiber optic communication systems. Fiber optic connectors allow two optical fibers to quickly connect and disconnect optically.

A typical fiber connector is a gland mount supported on a front end of a connector shell. The bushing assembly includes a bushing and a core mounted towards a rear end of the bushing. A spring is used to bypass the gland mount in a forward direction relative to the connector shell. The bushing functions to support an end portion of at least one optical fiber (in the case of a multi-fiber bushing, the ends of the multiple fibers are supported). The bushing has a front end face on which a polished end of the fiber optic is located. When two fiber optic connectors are interconnected, the front end faces of their respective bushings abut each other and the bushings are forced together by spring loads from their respective springs. With the fiber optic connectors connected, their respective optical fibers are coaxially aligned so that the end faces of the optical fibers directly oppose each other. In this way, an optical signal can be transmitted from one optical fiber to another optical fiber through the aligned end faces of the optical fibers. For many fiber optic connector styles, alignment between the two fiber optic connectors is provided through the use of a fiber optic adapter that receives the connectors, aligns the ferrules, and mechanically holds the connectors in a connected orientation relative to one another. other.

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A fiber optic connector is often secured to the end of a corresponding fiber optic cable by anchoring a tensile strength structure (for example, resistance elements such as aramid wires, fiberglass reinforced rods, etc.) of the cable with the connector that wraps around the connector. Anchoring is typically performed through the use of conventional techniques such as crimps or adhesives. Anchoring the cable pull resistance structure with the connector shell is advantageous in that it allows the tensile load applied to the cable to be transferred from the cable resistance elements directly to the connector shell. In this way, the tensile load is not transferred to the bushing assembly of the fiber optic connector. If the tensile load were applied to the bushing assembly, such traction load could cause the bushing assembly to be pulled in a proximal direction against deflection of the connector spring thereby possibly causing an optical disconnection between the connector and its corresponding mated connector. Fiber optic connectors of the type described above may be referred to as drag proof connectors. In other connector styles, the tensile strength layer of the fiber optic cable can be anchored to the core of the gland mount.

The connectors are typically installed on fiber optic cables at the factory using a direct termination process. In a direct termination process, the connector is installed on the fiber optic cable by securing an end portion of a fiber optic of the fiber optic cable to a socket on the connector. After the end portion of an optical fiber has been secured in the socket, the end face of the socket and the end face of the optical fiber are polished and otherwise processed to provide an acceptable optical interface at the end of fiber optics. A direct termination is preferred because it is fairly simple and has no losses of the type associated with a spliced ​​connection.

A number of factors are important regarding the design of a fiber optic connector. One aspect relates to the ease of manufacturing and assembly. Another aspect relates to the size of the connector and the compatibility with the legacy equipment. Still another aspect relates to io's ability to provide high-quality signal connections with minimal signal degradation.

COMPENDIUM

The present disclosure relates to fiber optic connectors which have fusion splices in the body. In certain embodiments, the connectors are configured to be fully compatible with legacy equipment such as standard patch panels and standard fiber optic adapters. In other embodiments, such connectors may include factory fusion splices. In certain modalities, the connectors fully comply with Telcordia GR-326 or similar strict industrial or Client specifications (for example, TIA-EIA 568-C.3; IEC 61753-X; and IEC 61755-X). In certain modalities, the connectors fully comply with Telcordia GR-326 or similar strict industry or customer specifications regarding the length and side load test. In certain embodiments, these connectors are less than or equal to the 57-millimeter long GR-326 requirement.

Various manufacturing methods are disclosed for making the disclosed connectors and other components. In one method, an injection molding process is used in which an ultraviolet (UV) curable material is introduced into a mold cavity formed by a pair of molding blocks where the material is cured by UV light while remaining still in the mold cavity. In one embodiment, the process is used to form an overmolded part into a component. In one embodiment, the component is a socket on a fiber optic connector.

A variety of additional aspects will be established in the following description. Aspects relate to individual characteristics and combinations of characteristics. It should be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive concepts upon which the modalities disclosed herein are based.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front, perspective cross-sectional view of a bushing assembly in accordance with the principles of the present disclosure;

Figure 2 is a rear perspective view of the bushing assembly of Figure 1;

Figure 3 is a longitudinal cross-sectional view of a bushing assembly of Figure 1 with a dust cap installed on the bushing;

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Figure 4 is a cross-sectional view taken along section line 4-4 of Figure 3, the cross-sectional view shows a stripped fiber portion of an optic fiber of the bushing assembly;

Figure 5 is a cross-sectional view taken along section line 5-5 of Figure 3, the cross section shows a covered fiber portion of the bushing assembly;

Figure 6 is a cross-sectional view showing an alternative configuration of the coated fiber portion of Figure 5;

Figure 7 is a flow chart illustrating a process sequence io for manufacturing the bushing assembly of Figure 1;

Figure 8 is a side view showing the gland assembly of Figure 1 in the polishing process on a polishing table;

Figure 9 is a top view of the bushing assembly and polishing table of Figure 8;

Figure 10 shows the bushing assembly of Figure 1 in the refining process with respect to the concentricity of the core;

Figure 11 is an end view of the bushing assembly of Figure 1 with the bushing marked for purposes of fine tuning the concentricity of the core;

Figure 12 is a graph used as a tool to determine the direction of core offset established during fine tuning of core concentricity;

FIG. 13 is a front, perspective, cross-sectional view of a fiber optic connect and cable assembly in accordance with the principles of the present disclosure;

Figure 14 is another cross-sectional view of the fiber optic connector and the cable assembly of Figure 13, the connection is shown without a dust cap;

Figure 15 is a longitudinal, cross-sectional view of the fiber optic connector and cable assembly of Figure 13;

Figure 16 is a flow chart illustrating a sequence of steps for manufacturing the fiber optic connect and cable assembly of Figure io 13;

Figure 17 shows the socket assembly of Figure 1 which is maintained for laser peeling, cleaning and cleavage;

Figure 18 shows the fiber optic cable of the fiber optic connector and the cable assembly of Figure 13 with its fiber optic maintained for laser stripping, cleaning and cleavage;

Figure 19 shows the optical fiber of the socket assembly of Figure 1 in approximate alignment of the optical fiber of the optical fiber cable;

Figure 20 shows the bushing fiber precisely aligned with the fiber of the optical fiber cable, the aligned fibers are shown in an arc treatment station, an arc shield is also shown;

Figure 21 shows the arrangement of Figure 20 with the shield decreased to protect the ferrule and coated portions of the δ fibers

when the arc treatment device is activated to form a fusion joint between the aligned optical fibers;

Figure 22 shows the arrangement of Figure 21 after an initial protective coating or on a mold layer has been formed on the fusion joint;

Figure 23 shows the arrangement of Figure 22 after a core has been overmolded onto the rear portion of the bushing of the bushing assembly and further on to the joint between the aligned fibers;

Figure 24 is a cross-sectional view illustrating a mold for forming the overmolded core of Figure 23;

Figure 25 is a perspective view of the bushing assembly of Figure 1 spliced ​​with the fiber optic cable and over-molded with the core;

Figure 26 is a front end view of another fiber optic connector in accordance with the principles of the present disclosure;

Figure 27 is a cross-sectional view taken along section line 27-27 of Figure 26;

Figure 27A is an enlarged view of a portion of Figure 27;

Figure 28 is a front end view of another fiber optic connector in accordance with the principles of the present disclosure;

Figure 29 is a cross-sectional view taken along section line 29-29 of Figure 28;

Figure 29A is an enlarged view of a portion of Figure 29;

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Figure 30 is a front end view of another fiber optic connector in accordance with the principles of the present disclosure;

Figure 31 is a cross-sectional view taken along section line 31-31 of Figure 30;

Figure 31A is an enlarged view of a portion of Figure 31;

Figure 32 is a front end view of another fiber optic connector in accordance with the principles of the present disclosure;

Figure 33 is a cross-sectional view taken along section line 33-33 of Figure 32;

Figure 33A is an enlarged view of a portion of Figure 33;

Figure 34 is a front end view of another fiber optic connector in accordance with the principles of the present disclosure;

Figure 35 is a cross-sectional view taken along section line 35-35 of Figure 34;

Figure 35A is an enlarged view of a portion of Figure 35;

Figures 36-40 show an example manufacturing sequence for splicing a fiber termination end of a gland with a fiber of a cable and for enclosing the splice and a portion of the gland within a composite core suitable for use in any of the fiber optic connectors disclosed herein;

Figure 41 illustrates an appropriate multi-fiber bushing for use with multi-fiber connectors in accordance with the principles of the present disclosure, the multi-fiber bushing is shown supporting a fiber optic termination having a plurality of optical fibers;

Figure 42 illustrates a multi-fiber optic connector of Figure 41;

Figures 43-48 illustrate a sequence of steps for preparing a multi-fiber optic cable 5 for splicing with the fiber-optic termination end of the multi-fiber bushing of Figure 41;

Figures 49-51 show a sequence of process steps to prepare the fiber optic termination of the multi-fiber bushing of Figure 41 for splicing with the multi-fiber cable of Figures io 43-48;

Figure 52 is a perspective view of a fusion splice tray according to the principles of the present disclosure for use in fusion splicing the multi-fiber cable of Figures 43-48 with the fiber end cap of the ferrule of Figure 41;

Figure 53 is a top view of the fusion splice tray of Figure 52;

Figure 53A is an enlarged view of a portion of Figure 53;

Figure 54 is a cross-sectional view taken along section line 54-54 of Figure 53;

Figure 54A is an enlarged view of a portion of Figure 54; and

Figures 55-62 show a sequence of steps for assembling the multi-fiber connector of Figure 42 after the fiber termination end

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the multi-signature bushing of Figure 41 has been spliced ​​with the multi-fiber cable of Figures 43-48;

Figures 63-67 show an alternative embodiment showing a manufacturing sequence for splicing a fiber end cap of a ferrule with a fiber of a cable and for wrapping the splice and a portion of the ferrule within a composite core suitable for use in any of the fiber optic connectors disclosed herein in accordance with the principles of the present invention;

Figure 68 is a pre-assembled representation of a bushing and flange in accordance with the principles of the present invention;

Figure 69 is a side view of Figure 68;

Figure 70 is a cross-sectional view taken along section line 70-70 of Figure 69;

Figure 71 is a top view of Figure 68;

Figure 72 is a perspective view of the bushing assembly of the

Figures 63-65 spliced ​​with the fiber optic cable and over-molded with the core;

Figure 73 is a side view of Figure 72; and

Figure 74 is a cross-sectional view taken along section line 74-74 of Figure 73;

Figure 75 is a front perspective view of one embodiment of the mold assembly in accordance with the principles of the present disclosure;

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Figure 76 is a side view of the mold assembly shown in Figure 75;

Figure 77 is a bottom perspective view of the mold assembly shown in Figure 75;

Figure 78 is a cross-sectional view of the mold assembly shown in

Figure 75;

Figure 79 is an enlarged cross-sectional view from a portion of the mold assembly view illustrated in Figure 78;

Figure 80 is a top view of the cavity portion of an upper or lower part of the mold assembly shown in Figure 75;

Figure 81 is a top view of a cavity portion of a lower part of the mold assembly shown in Figure 75;

Figure 82 is a flow chart of an injection molding process that can be used with the mold assembly shown in Figure 75;

Figure 83 is an exploded view of another bushing and core assembly in accordance with the principles of the present disclosure;

Figure 84 is a partially assembled view of the bushing and core assembly of Figure 83;

Figure 85 is a side view of the bushing assembly of Figure 83 20 with a front core portion over-molded onto the bushing;

Figure 86 is a rear perspective view of the bushing assembly and the front core portion of Figure 85;

Figure 87 is an exploded view of another bushing and core assembly in accordance with the principles of the present disclosure;

Figure 88 shows the bushing and core assembly of Figure 87 in a partially assembled configuration;

Figure 89 is a perspective view of a bushing liner and core assembly of Figures 87 and 88;

Figure 90 is an exploded view of yet another bushing and core assembly in accordance with the principles of the present disclosure;

Figure 91 shows an alternative core coating that can be used with the gland and the front core portion of the embodiment of Figures and 88;

Figure 92 is an exploded view illustrating an LC style connector incorporating the socket and core assembly of Figures 83 and 84; and

Figure 93 is a cross-sectional view of the connector of Figure 92.

DETAILED DESCRIPTION

Figures 1 and 2 illustrate a bushing assembly 20 in accordance with the principles of the present disclosure. The gland mount 20 includes a gland 22 and a fiber optic termination 24 secured to gland 22. The fiber optic termination 24 may be referred to as a "first fiber optics." Cap 22 includes a front end 26 positioned opposite of a rear end 28. The front end 26 preferably includes an end face 30 where an interface end 32 of the fiber optic termination line 24 is located. The socket 22 defines an inner diameter of the socket 34 which extends through the socket 22 from the end front 26 to rear end 28. The fiber optic end cap 24 includes a first portion 36 secured on the inside diameter of the socket 34 and a second portion 38 extending rearward from the rear end 28 of the socket 22. The second portion 38 may be referred to as a "pigtail "Or as a" free end portion. "

Cap 22 is preferably constructed of a relatively hard material capable of protecting and supporting the first portion 36 of the fiber optic termination line 24. In one embodiment, cap 22 has a ceramic construction, or In other embodiments, cap 22 may be made from alternative materials such as Ultem, thermoplastic materials such as Polyphenylene Sulfide (PPS), other engineering plastics, or various metals. In exemplary embodiments, bushing 22 has a length L1 in the range of 5-15 millimeters (mm), or in the range of 8-12 mm.

The first portion 36 of the fiber optic end cap 24 is preferably secured by an adhesive (eg epoxy) with the inside diameter of the cap 34 of the cap 22. The interface end 32 preferably includes a polished end face accessible at the front end 32 d I bushing 22.

Referring to Figure 3, the inside diameter of bushing 34 has a staggered configuration with a first inside diameter segment 40 having a first diameter d1 and a second inside diameter segment 42 having a second diameter d2. The second diameter d2 is larger than the first diameter d1. A first diameter passage 44 provides a transition from the first diameter d1 to the second diameter d2. The first ID segment 40 extends from the front end 26 of the sleeve 22 towards the diameter passage 44. The second ID segment 42 extends from the diameter passage 44 towards the rear end 28 of the sleeve 22. The diameter The interior of the bush 34 further includes a conical transition 39 extending from the second bore 42 to the rear end 28 of the bush 22. In certain embodiments, the first diameter d1 is approximately 125.5 microns with a tolerance of +1 micron. In certain io modalities, the second diameter d2 may be approximately 250 microns to accommodate a coated optical fiber, or approximately 900 microns to accommodate a coated and damped optical fiber. In one example, d1 is in the 230-260 micron range and d2 is in the 500-1100 micron range.

The first portion 36 of the fiber optic termination line 24 includes a stripped fiber segment 46 that fits in the first ID 40 segment of the sleeve 22 and a coated fiber segment 48 that matches the second ID 42 segment of the bushing 22. The stripped fiber segment 46 is preferably bare glass and, as shown in Figure 4, includes a core 47 surrounded by a cladding layer 49. In a preferred embodiment, the stripped fiber segment 46 has an outer diameter that is not more than 0.4 microns smaller than the first diameter d1. In certain embodiments, the coated fiber segment 48 includes one or more coating layers 51 that surround the coating layer 49 (see Figure 5). In

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In certain embodiments, the coating layer (s) 51 may include a polymeric material such as acrylate having an outside diameter in the range of about 230-260 microns. In still other embodiments, the overlay layer / layers 51 may be surrounded by a buffer layer 53 (eg, a fitted or loose buffer layer) (see Figure 6) having an outside diameter in the range of about 500- 1100 micras.

The second portion 38 of the fiber optic termination line 24 preferably has a length L2 that is relatively short. For example, in one embodiment, the length L2 of the second portion 38 is less than the length L1 or i of the sleeve 22. In even other embodiments, the length L2 is not more than 20 mm, or is not more than 15 mm, or not it is more than 10mm. In still other embodiments, the length L2 of the second portion 38 is in the range of 1-20 mm, or in the range of 1-15 mm, or in the range of 1-10 mm, or in the range of 2- 10mm, or in the range of 1-5mm, or in the range of 2-5mm, or less than 5mm, or less than 3mm, or in the range of 1-3mm.

Figure 7 outlines a process for manufacturing the bushing assembly 20 of Figures 1-3. The manufacturing process begins at step 100 where bush 22 is fed to a processing station or location. It will be appreciated that bushing 22 can be fed by an automated feeding mechanism such as a bowl feeding mechanism.

Once bushing 22 has been selected and fed, or conversely moved towards the processing station, the inside diameter of the

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bushing 22 is preferably measured (see step 102). For example, the first diameter d1 defined by the first inner diameter segment 40 of the inner diameter of the bush 34 is preferably measured. An automated bushing handler (eg, clamp / holder 37 as schematically shown in Figure 8) can receive bushing 22 from the automated wire drive and can hold and / or manipulate bushing 22 during measurement.

Once the first diameter d1 of the inner diameter of the socket 34 has been determined, an appropriate optical fiber is selected for insertion or into the socket (see step 104). Preferably, a plurality of fiber reels 60a-60d is provided at the processing station. Each of the fiber reels 60a-60d includes a separate fiber optic 62a-62d. Each of the optical fibers 62a-62d preferably has a different cladding outer diameter. It is convenient to select the optical fiber 62a-62d qu 15 has a cladding outer diameter that is closer to the measured diameter d1 of the bushing 22. In certain embodiments, the first measured diameter d1 is not more than 0.4 microns larger than the outer diameter cladding of selected optical fiber 62a-62d.

To improve the concentricity of the core with respect to the outside diameter 20 of the sleeve 22, it is desirable for the optical fibers 62a-62d to be high-precision optical fibers in which parameters such as cladding outer diameter and core-a concentricity -Coating are manufactured to a relatively tight tolerance. In certain embodiments, each of the optical fibers 62a-62d has a fabricated outer jacket diameter with a tolerance of +/- 0.7 microns and also has a core-to-clad concentricity offset less than or equal to 0.5 microns ( that is, the center of the core is displaced from the center of the cladding diameter by no more than 0.5 microns). The bushing 22 is also preferably manufactured to relatively precise tolerance specifications. For example, in one embodiment, the diameter d1 of the bush has a dimension of 125.5 microns plus 1.0 microns, minus 0.0 microns. Additionally, bushing 22 may have a concentrically offset fiber inner diameter less than or equal to 1 miera (i.e., the center of the bushing inner diameter is offset from the center of the bushing outer diameter by no more than 1 miera). By using a precision socket in combination with a precision optical fiber, and having several precision optical fibers of different size from which the optical fiber to be inserted into the socket is selected, it is not possible to optimize the concentricity of the optical fiber on bush 22 without rotary tuning and even more with rotary tuning. In an economically reasonable embodiment, four fibers of known diameters of 125.3 microns, 125.6 microns, 125.9 microns, and 126.2 microns could be used to match the ID of the bushing with 0.2 to 0.3 microns. Using this fiber selection process as part of the manufacturing process, it is possible that all bushing assemblies 20 exiting the manufacturing process have a first measured diameter d1 that is not more than 0.4 microns larger than the jacket OD. of the selected optical fiber 62a-62d. Those that are out of tolerance can be rejected, but thanks to the process only a relatively small number can be out of tolerance, thereby improving the profitability of the process. In other embodiments, the fabricated and output bushing assemblies 20 according to the process may have first measured diameters d1 that on average are not more than 0.4 microns larger than the cladding outer diameters of the selected optical fiber 62a-62d.

Once the fiber optic 62a-62d of the appropriate diameter has been selected, the fiber optic is cut to length to form the fiber optic of the end strand 24 (see step 106). In certain embodiments, the 24 corta cut optical fiber is less than 40 microns in length. In other embodiments, the optical fiber 24 has a length of less than 30 microns, or less than 25 microns, or less than 20 microns, or less than 15 microns. In even other modalities, the cut optical fiber has a length in the range of 12-25 microns.

In step 108, the optical fiber 24 is separated. By separating the optical fiber 15 24, the stripped fiber segment 46 is exposed. The stripped fiber segment 46 preferably includes a glass core 47 and a cladding 49 as shown in Figure 4. The cutting and separating steps can be automated. .

After separating the optical fiber 24, the epoxy is dispensed into the core of the bushing 34 from the bushing 22 (see step 110), and the optical fiber 24 is inserted into the core of the bushing 34. Due to the relatively close tolerance between the first diameter d1 of the stripped fiber segment 46 of the fiber optic terminal 24 and the first portion 36 of the fiber core 34, the surface tension between the epoxy in the core of the bush 34 and the Fiber Optic End Cap 24 provides an auto-centering feature that helps center stripped fiber segment 46 on the first ID bore 40. Said fiber insertion is indicated in step 112 of the process. Fiber Optic End Cap

24 is inserted into the inside diameter of the bushing 34 through the rear end of the bushing 22. During insertion, the termination end of the fiber optic 24 is oriented so that the stripped fiber segment 46 leads to the termination end of the fiber optic 24 through of the socket 22. After insertion, an end portion of the stripped fiber segment 46 projects outward from the end face 34 of the socket 22. The epoxy delivery and fiber insertion stages can be automated. During these stages, the bushing can be supported by the automated bushing handler.

In step 114, the bushing assembly 20 is cured (i.e., oven cured), cooled, and cleaved. It is noted that the curing process is particularly efficient because ferrule 22 can be directly heated and heat does not have to pass through a connector element or other structure surrounding ferrule 22. Similarly, the cooling process is efficient since only the socket 22 and the fiber optic end cap 24 need to be cooled. Excision can be performed using a laser or a mechanical excision tool. The curing, cooling and cleavage stages can be automated.

Once the termination end of the fiber optic 24 has been cleaved adjacent to the end face 30 of the sleeve 22, the cleaved end of the interface of the fiber optic 24 can be polished as indicated in step 116. It will be appreciated that The polishing process can include multiple polishing stages using different polishing pads and polishing compounds that have different degrees of abrasiveness. Since the gland mount 20 is not connected to an extended length of cable, the low vertical polishing pressure can be applied without lateral loading from a cable. The absence of an extended length of cable coupled to bushing 22 also allows bushing assembly 20 to be rotated about its axis 76 during the polishing process. In certain embodiments, the gland mount 20 can rotate about its axis 76 at a speed of at least 10 rotations per minute, or at least 50 rotations per minute, or at least 100 rotations per minute, or at least 500 rotations per minute.

Figures 8 and 9 show the end face of the bush 30 and the end of the interface 32 of the optical fiber 24 being polished using a polishing turntable 70 that rotates about an axis 72. A polishing pad 74 can be provided on the polishing turntable 70. In other embodiments, instead of rotation, the polishing table 70 may oscillate, reciprocate, move along a random orbit path, or move in another way. Additionally, during the polishing process, it may be desirable to rotate the sleeve 22 about its axis of rotation 76 as described above.

As shown in Figures 8 and 9, a mechanical polishing process is used to polish the end face 30 of the ferrule and the interface end of the fiber optic end cap 24. In other embodiments, a laser can be used for both the cleavage and the polishing process of the interface end 32 of the fiber optic terminal 24. By processing the end 32 of the terminal end of the optical fiber 24 with a laser, it may be desired to rotate the sleeve 22 about its axis 76 as described above.

The polishing steps described above can be automated.

During polishing, the bushing 22 can be supported by the automated bushing manipulator machine. In certain embodiments, the automated handling machine may include a rotary drive 35 to rotate bush 22 around its axis 76 during polishing or other steps described herein, since rotation of bush 22 about its axis is desired. central.

During the polishing process, it is desirable to interrupt the polishing and provide the tuning of the bushing assembly 20 (see step 118). It will be appreciated that tuning is a process in which a core displacement direction 47 is established and an indication of the core displacement direction is provided in the socket 22. Indication of the direction of travel of the core may include any number of techniques such as printing a mark on the socket 22, engraving a mark on the socket

22, or otherwise marking the bushing 22. The direction of travel of the core is the direction in which the core 47 is displaced from a center line (ie axis 76) of the bushing 22.

As shown in Figure 10, the socket assembly 20 can be fine-tuned by the glare of a light 80 through a rear end of the terminal end of the optical fiber 24 in such a way that the light is transmitted through the fiber optic terminal 24 and outside the interface end 32 of fiber optic terminal 24. A camera 82 or other structure can be used to view and monitor the light output through the core of the fiber 47 at the end 32 to determine the position of the core. Cap mount 20 is then rotated about its axis 76 while light 80 continues to be directed through the fiber optic terminal 24 and camera 82 continues to view end 32 of the fiber optic terminal 24. As the bushing assembly 20 is rotated about its axis 76, the core 47 of the fiber optic terminal 24 changes the elevations relative to a horizontal line H (see Fig. 11) that intersects the bushing centerline 76 22.

Figure 12 is a graph illustrating the height of core 47 with respect to horizontal line H as bushing 22 is rotated about its central axis 76. As shown in Figure 12, the maximum height of core 89 is indicative of a direction of travel 91 of the core 47 with respect to the axis 76 of the sleeve assembly 20. The axis 76 of the sleeve assembly 20 is defined by the outer diameter of the sleeve 22. Once the direction of displacement of the core 91 has been established, the bushing 22 can be marked accordingly such that the displacement direction can be identified at a later point in the manufacturing process. For example, as shown in Figure 11, a mark 93 is provided in alignment

<img file="MX338237B_D0014.tif" />

direct with the direction of travel of the core 91. In other embodiments, the marking could be shifted 180 ° from the direction of travel of the core 91 or elsewhere in the gland 22. When gland mount 20 is installed subsequently on a connector element, marking 93 is used to orient the movement of the core to a desired location relative to the center connector element. For example, in a preferred embodiment, the direction of travel of the core 91 is oriented at the twelve o'clock position relative to the connector element. Marking 93 can also be used to orient the displacement of the core relative to a core that is subsequently mounted to bush 22. The core may include a clamping structure to ensure that the bushing is mounted in a desired rotational position within the connector element such that the displacement of the core is oriented in a desired rotational position relative to the connector element.

Because bushing assembly 20 is tuned prior to insertion into a connector element and / or prior to core assembly in bushing 22, tuning can be provided in an infinite number of increments (i.e. the marking location can be chosen from an infinite number of rotational / circumferential positions around the center line of the bushing) to provide precise alignment of the marking 93 with the direction of travel of the core 91. In another embodiment, the marking location can be chosen from a discrete number of rotational / circumferential s positions around the center line of the bushing, where the number of discrete rotational / circumferential positions is ai minus 6, or at least 12 , or at least 18, or at least 24, or at least 30. In other examples, the bushing assembly 20 is tuned after at least a portion of the core is mounted on the bushing and the core can define a discrete number of rotational / circumferential positions. In such examples, an offset marking can be provided in the core. The tuning step can be automated and the rotation of the bushing22 during the tuning can be accomplished by the automated bushing manipulator machine.

After tuning, the polishing process is completed on the ♦ io 116 cap and various inspections are carried out at step 118. Inspections may include a standard corporate workmanship inspection in which end 32 of the terminal cape Fiber optic 24 is inspected with a microscope to ensure there are no unacceptable scratches, holes or chips on the front surface. The end face 32 of the fiber optic terminal end 24 and the end face 30 of the sleeve 22 can also be inspected and analyzed to ensure that the end faces conform to certain end face geometry specifications. Finally, a continuity inspection can be carried out by I which light shines through the fiber optic terminal 24 to ensure that the fiber optic terminal 24 is capable of transmitting light. After the continuity inspection has been completed, a dust cap can be installed on gland 22 and gland assembly 20 can be packaged as shown in step 120. The various stages described above can be automated.

Figures 13-15 illustrate the assembly of a fiber optic cable and connector 200 in accordance with the principles of the present disclosure. The fiber optic cable and connector assembly 200 includes a fiber optic connector 202 having a connector element 204. The connector element has a front end 206 and a rear end 208. The socket assembly 20 is positioned at least partially within connector element 204. Specifically, the socket assembly 20 is positioned with the socket 22 located adjacent to the front end 206 of the connector element 204. The fiber optic connector 202 further includes a sleeve 210 mounted adjacent to the rear end 208 of the connector element 204. As used herein, the word adjacent means at or near. In a preferred embodiment, connector 202 is compatible with existing connectors, fiber optic adapter, switch panels, and fiber optic cables.

The fiber optic cable and connector 200 assembly further includes a fiber optic cable 212 extending through sheath 210. Fiber optic cable 212 includes an outer jacket 214 and an optical fiber 216 located within the jacket Exterior 214. Optical fiber 216 may be referred to as a "second optical fiber". Fiber optic 216 is optically connected in a fusion splice 217 to fiber optic 24 of socket assembly 20. Fusion splice 217 is positioned at a splice location 218 separate from trailing end 28 (i.e., base) of bushing 22. In one embodiment, splice location 218 is within connector element 204 and is positioned not to more than 20 mm from the rear end 28 of the bushing 22. The fusion splice 217 is preferably a factory fusion splice. A factory fusion splice is a splice made in a manufacturing facility as part of a manufacturing process. In one embodiment, the 202 fiber optic connector fully complies with Telcordia GR326 or similar strict industry or customer specifications. In other examples, the splice can be a field splice.

Referring to Figure 15, connector element 204 includes a front piece 220 and a back piece 222. Front piece 220 forms a front end interface of fiber optic connector 202 and back piece 222 is configured to allow reinforcing elements 224 (i.e., aramid yarn, fiberglass, or other reinforcing elements capable of providing reinforcement in the traction to the fiber optic cable 212) of the fiber optic cable 212 are anchored. In certain embodiments, stiffening elements 224 can be attached to back piece 222 of connector element 204 with a mechanical retainer such as a crimping sleeve. In other embodiments, adhesives or other means can be used to secure reinforcing elements 224 to connector element 204.

Still referring to Figure 15, the front and rear pieces 220,

222 The connector element 204 is interconnected to each other by a connection such as a snap connection, an adhesive connection, or other type of connection. When the front and rear parts 220, 222 are connected to each other, a spring 228 and a core 230 are captured between the front and rear parts 220, 222. The core 230 is secured on the rear end 28 of the bushing 22. Core 230 also covers splice location 218 such that fusion splice 217 is located within core 230. In one embodiment, an intermediate layer 232 (ie, a liner layer, the top mold layer). , or other layer) is provided between the fusion splice 217 and the core 230. Spring 228 is captured within a spring cavity 229 defined by back piece 222 and functions to bypass core 230 and bushing assembly 20 which is performed with core 230 io in a forward direction relative to the connector element 204. Core 230 is a structure secured in bushing 22 such that bushing 22 and core 230 move together as a unit. In certain embodiments, core 230 provides the structure against which the bypass of spring 228 can be applied to bypass core 230 and bushing 22 forward with respect to connector element 204. Core 230 also includes a structure that interferes with an internal structure (i.e., a stop) of connector element 204 to limit forward movement of bushing 22 and to prevent bushing 22 from being pushed off the front of the element of connector 204 by spring 228. Core 230 and splice location 218 can be placed within the spring cavity

229. Insulator knob 210, back piece 222, and spring 228 may all have internal dimensions (i.e., internal diameters) larger than an external dimension (i.e., outer diameter) of cable 212 such that during assembly / fabrication of sheath 210, back piece 222 and spring 228 can be slid back on outer shell 212 to provide clearance / clearance for splicing and core application to splice 217.

In the embodiment shown, fiber optic connector 202 is shown as a standard SC type connector. As such, fiber optic connector 202 is adapted to be received within an SC type fiber optic adapter that is used to couple two of the fiber optic connectors to each other to provide an optical connection between them. Fiber optic connector 202 io includes a release sleeve 236 that is slidably mounted on connector element 204. When fiber optic connector 202 is inserted into a fiber optic adapter, the protrusions of connector element 204 they are engaged by latches on the fiber optic adapter to retain fiber optic connector 202 within the fiber optic adapter. To release the fiber optic connector 202 from the fiber optic adapter, the release sleeve 236 is slid back with respect to the connector element 204 thereby causing the latches of the fiber optic adapter to disengage from the protrusions of the element of the connector 204 so that the fiber optic connector 202 can be removed from the fiber optic adapter. An exemplary fiber optic adapter is disclosed in US Patent No.⁰5,317,663, which is incorporated herein by reference in its entirety.

In a preferred embodiment, the location of the fitting 218 is relatively close to the rear 28 of the socket 22. For example, in one embodiment, the location of the fitting 218 is not more than 15 mm from the socket 22. In another embodiment, the location of the joint 218 is not more than 10 mm from the bushing 22. In yet another embodiment, the location of the joint 218 is not more than 5 mm from the bushing 22. In additional embodiments, the splice location is spaced 1-20mm from bushing 22, or 1-15mm from bushing 22 or spaced 1-10mm from bushing 22, or 1-5mm from bushing 22 , or 2 -10 mm from bushing 22, or 2-5 mm from bushing 22, or 1 - 3 mm from bushing 22, or less than 4 mm from bushing 22, or less than 3 mm from of bushing 22, or 1 - 4 mm from bushing 22, or 2-3 mm from bushing 22.

To the extent that in some embodiments of the present disclosure a connecting mouth cannot be provided, the splice location 218 (i.e. the interface between the two optical fibers 24, 216) is preferably located in the region, which would normally be occupied by a connecting mouth. In certain embodiments, the splice location is provided between the base of bushing 22 and the rear end of spring 228. In certain embodiments, the splice location 218 is within the chamber of spring 229. In certain embodiments, spring 228 shunts bushing 20 to a more forward position (ie, a more distal or non-connected position) and During a connection to another connector, spring 228 allows bushing 22 to move backward from the forward position, against spring movement.

228, to a posterior position (i.e., the proximal position or connected position). In certain embodiments, the splice location 218 is located between front and rear ends 228a, 228b of spring 228 when the bushing is in the forward position, and is also located between front and rear ends 228a, 228b of spring 228 when the bushing 22 is in the rear position.

In certain embodiments, core 230 has a polymeric construction that has been over-molded on the rear end of bushing 22 and on splice location 218. By protecting fusion splice 217 within core 230 at a location in proximity to the bushing 22, it is possible to manufacture a fiber optic connector that is relatively short in length. In a preferred embodiment, the fiber optic connector 202 has a length L3 that is less than 57 mm. It will be appreciated that the length L3 of the fiber optic connector 202 is measured from the front end 26 of the bushing 22 to a rear end

240 of the sheath 210. In certain embodiments, a portion 231 of the core 230 extending rearwardly from the bushing 22 has a length L4 that is shorter than the length L1 of the bushing 22. In certain examples, the location of splice 218 is within 5 mm from the rear end of the bushing 22. Providing the splice location 218 within 5 mm of the rear end of the gland 22 aids in the design of the fiber optic connector in accordance with industry standard or customer-side load and connector length specifications (en (say, GR-326 side load and length requirements).

Sleeve 210 is shown snap-fit ​​over back piece 222 of connector element 204. Specifically, sleeve 210 is snap-fit ​​over the location where stiffening elements 224 are attached to connector element 204. It will be appreciated that sheath 210 has a tapered, flexible configuration that provides fiber optic 216 with radius of curvature protection when a side load is applied to fiber optic connector 202 through fiber optic cable 212.

In one embodiment, fusion splice 217 is a factory fusion splice having an insert loss-related splice of 0.1 io or decibel or less, 0.05 decibel or less, or 0.02 decibel or less n signal wavelength range from 1260 manometers to 1630 nanometers. Furthermore, in preparing the optical fibers for fusion splicing 217, an active alignment system can be used to precisely align the optical fibers 216, 24. The example active alignment systems are sold by Sumitomo, Furukawa, Vytran, 3SAE, and Fujikura. In certain modalities, the active alignment system can ensure that the core centers of the spliced ​​optical fibers 216, 24 move no more than 0.01 microns through the alignment system prior to splicing. The alignment system may use cameras that view the cores of the optical fibers 216, 24 along the viewing lines that are perpendicular to each other (eg, top view and side view).

As described above, in certain embodiments, the fiber optic end cap 24 can be manufactured using a precision fiber having narrow tolerance parameters as the core for concentricity cladding and outer diameter variation cladding. In this regard, in certain embodiments, the fiber optic end cap 24 may be different (i.e. may have a different construction, different mechanical characteristics, different physical attributes, different optical performance characteristics, different degrees of precision, etc.) than fiber optic 216 of the fiber optic cable. For example, fiber optic termination cable 24 may be an optical fiber manufactured with greater precision than fiber optic 216 of fiber optic cable 212 (i.e., the fiber termination cable is manufactured to tighter tolerances than fiber optic cable 216). For example, in certain embodiments, the termination strand of fiber optic 24 may have a better average core for cladding concentricity than fiber optic 216. Furthermore, the outside diameter of the fiber optic end cap liner 24 may be more precisely tolerated than the outside diameter of the fiber optic liner 216. In addition, the fiber optic end cap 24 may have one (ie, less ) different fiber cut-off wavelength than optical fiber 216. On the other hand, the termination line of the optical fiber 24 can have different coating mode suppression characteristics as compared to the optical fiber 216. For example, compared to the optical fiber 216, the termination line of the optical fiber 24 it may have a construction adapted to provide enhanced mode suppression of coating to suppress modal interference. Exemplary optical fibers having constructions adapted to reduce / eliminate modal interference are disclosed in US Patent Nos. 6,498,888; 5,241,613; and 4,877,306, which are incorporated herein by reference in their entirety.

It is recognized in the art that splices can introduce losses (ie, insert loss, return loss). However, the fiber optic cable assembly and connector 200 of the present disclosure includes several features that provide excellent performance despite the presence of an internal splice. Such features include: a) the precise core-to-core alignment of the spliced ​​optical fibers; b) the precise centering of the fiber optic terminal end 24 inside the socket hole 34, the precise tuning io of the direction of movement of the core inside the connector element, and the precise centering of the socket hole 34 inside the socket 22 .

In some embodiments, fiber optic connector 202 may be in full compliance with Telcordla GR-326 requirements. Specific sections of the Telcordia GR-326 in which the 202 fiber optic connector may be in compliance include sections related to transmission with applied load, installation tests, and the post-condensation thermal cycle test.

FIG. 16 shows a process for manufacturing a switching cord formed by mounting fiber optic connectors 202 at opposite ends of fiber optic cable 212. In method step 300, fiber optic cable 212 is wound. and the components of the fiber optic connectors 202 are assembled. Next, in step 302, the ends of the outer sheath 214 of the fiber optic cable 212 are then cut and fragmented, and the reinforcing layer 224 is trimmed. As prepared, end portions of optical fiber 216 extend outward from each end of outer jacket 214. The end portions of optical fiber 216 are then disassembled, cleaned, and cleaved (ie, laser cleaved). (see step 304). During disassembly, cleaning, and cleavage, the end portions of the optical fiber 216 may be grasped on a bracket 217 (i.e., a clamp clip or other structure) (see Figure 18).

In step 306, bushing assembly 20 is fed (i.e. bowl fed) to a bracket 240 or brackets that grip / hold the bushing 22. An example bracket 240 is shown in Figure 17. In some or two embodiments, bushings 22 are oriented within supports 240 with tuning marks 93 at the twelve o'clock position, so that socket assemblies 20 can be subsequently loaded into their corresponding connector elements 204 in the twelve o'clock position. In this way, it is ensured that the direction of movement of the core is oriented in the upper position / sector of each connector. Although the twelve o'clock position is preferred, the direction of travel of the core can be set within the connector element at other rotational positions as well.

While each bushing 22 is supported by bracket 240, the free end of the fiber optic terminal 24 is removed, cleaned (eg, removed from the arc) and excised (eg, laser excised) (see step 308). ). It will be appreciated that the bushing assemblies 20 are prepared for each end of the switching cable.

Once the fibers have been disassembled, cleaned, and cleaved, the fiber optic terminal 24 of each gland mount 20 is aligned with a corresponding thick end portion of the fiber optic 216 (see Figure 19), and then aligned accurately (see Figure 20). Precise alignment of the optical fibers can be achieved using an active alignment device. By using the active alignment device, fiber 216 is held within supports 217 with an end portion of fiber 216 projecting outward from one end of support 217 (as shown in Figures 20 - 23, the cable 212 projecting from the opposite end of the support 217 has been omitted). Furthermore, bushing 22 is held within a cavity of bracket 240 while fiber 24 projects from the base of bushing 222 and is not directly contacted by bracket 240 or any other structure. Support 240 may include a clip or other structure that has two or more pieces that hold and hold bushing 22 during the active alignment of fibers 216, 24. The cavity of the bracket 240 may include an internal structure (i.e., a V-groove, a semicircular groove, etc. to align / position bushing 22). The end portions of the fibers are preferably unsupported (ie, not in direct contact with a structure such as a V-groove). In one example, the fiber 24 projects less than 5 mm from the base end of the bushing 22. This relatively short length facilitates the active alignment process. In certain examples, the central axis of the fiber 24 has an angle of not more than 0.1 degree with respect to the center line of the bushing. This also aids the active alignment process. While ideally there is no angular displacement between the central axis of fiber 24 and bushing 22, the length of the short end rope of fiber 24 helps to minimize the effect during active alignment of any angular displacement that may exist. Robotic systems are preferably used to manipulate supports 240, 217 to achieve axial alignment between fiber cores 24, 216. Because the alignment is not based on contact with extended lengths of fibers 24, 216 with the Alignment structure such as V-grooves, the splice location can be provided in close proximity to the base of the bushing 22 (eg, within 5mm of the io base). In certain embodiments, only splices in which the core centers of the spliced ​​optical fibers 216, 24 are displaced by no more than 0.01 microns are acceptable, and splices that fall outside this parameter are rejected. In other embodiments, the average core displacement for fibers spliced ​​by the process is less than 0.01 microns.

After precise axial alignment has been achieved, a shielding unit 250 descends on splice location 218 and a fusion splice machine 251 (i.e., an arc treatment machine) is used to melt the optical fibers 24 , 216 together. Shielding unit 250 includes shielding portions for shielding bushing 22 and clad portions of optical fibers 24, 216 intended to be spliced ​​together. The shield structure 250 may have a ceramic construction, polyether ether ketone (PEEK) construction, another heat resistant plastic construction, or other type of heat resistant construction. Preferably, shield structure 250 includes a crack g through which an arc or other power source of fusion splicing machine 251 can pass fusion splicing the optical fibers 24, 216 together. Preferably, crack g is 1-3mm, or 2- 2.5mm. Figure 20 shows the shield structure 250 in the elevated orientation and the

Figure 21 shows the shield structure in a shield position. The shielding structure may include side walls 253 that protect the sides of the bushing 22 and extend along the lengths of the optical fibers 24, 216, and transverse walls 255 that extend between the side walls 253. Transverse walls 255 extend through optical fibers 24, io or 216 (ie, transverse to optical fibers 24, 216) and include grooves 257 for receiving optical fibers 24, 216. Side walls 253 also protect portions of fibers 24, 216 adjacent the splice location and supports 214, 240. Transverse walls 255 protect fibers 24, 216, trailing end 28 of bushing 22, and supports 214, 240. A bridge section extends through the gap g between the transverse walls 255. Step 310 in Figure 16 is representative of the alignment, shielding, and fusion splicing operations.

After the fusion splice has been completed, a protective layer 232 may be placed, applied or otherwise provided on the optical fibers 24, 216 in the region between the rear end 28 of the sleeve 22 and a buffered / coated portion of fiber optic 216. In one example, protection layer 232 extends fully from trailing end 28 of bushing 22 to a buffered, coated portion of fiber optic 216. As shown, the coated and buffered portion of optical fiber 216 includes coatings in the form of 220-260 micron acrylate layers covering the glass portion of the optical fiber, and a buffer layer 221 (i.e., a loose or tight cushioning tube) having an outside diameter ranging from 500 - 1,100 microns. In Figure 22, shield layer 232 is shown extending over splice location 218 completely from trailing end 28 of bushing 22 to damping layer of optical fiber 216. In one embodiment, shield layer 232 is generally cylindrical (see Figure 15) and has a diameter slightly larger than the buffer layer and generally the same as a larger diameter of the conical transition 39 of the socket 34. In other embodiments, the protective layer 232 may have a truncated conical configuration (see Figure 22) with a larger diameter generally equal to the outer diameter of the bushing 22 and a smaller diameter generally equal to the outer diameter of the fiber buffer layer. Optics 216. It will be appreciated that the protective layer 232 can be applied using a top mold casting technique. Alternatively, coating, spraying, laminating, or other techniques can be used to apply the protective layer.

In certain embodiments, the protective layer 232 is made of a material that is softer (i.e., has a lower hardness) than the material used to make the core 230. In certain embodiments, the disassembled portion of optical fiber 216 has an inner liner layer that surrounds the liner layer, and shield layer 232 has mechanical attributes such as softness / hardness that substantially match or are comparable to mechanical attributes. of the inner liner layer of the disassembled portion of the optical fiber 216. In certain embodiments, the protective layer s 232 may be made of a thermoplastic material, a thermoset material (a material in which crosslinking is established during heat cure), other types of crosslinked materials, or other materials. Example materials include acrylates, epoxies, urethanes, siicones, and other materials.

At least some of the materials may be UV curable (that is, the materials cure when exposed to ultraviolet radiation / light). An example material includes a UV curable splice compound such as DSM-200 which is sold by DSM Desotech, Inc. of Elgin Illinois. In certain embodiments, an injection molding process (i.e., a thermoplastic injection molding process) can be used to apply and form shield layer 232 over splice location 218.

Once the protective layer 232 has been applied and cured, the core 230 is preferably over-molded onto the protective layer 232 as shown in Figure 23. The core 230 is preferably over-molded onto the rear end 28 of the bushing 22 and also on the junction location 218. Figure 24 shows mold parts 400a, 400b of a mold assembly 400 having an inner shape that matches the outer shape of the core 230. Mold assembly 410 is shown in Figures 75 81, described below, can also be used to form core 230.

Preferably, a polymeric material is injected from an injection machine 403 into a cavity 401 defined by the mold pieces 400a, 400b to over-mold the polymeric material over the splice location 218 and the rear end 28 of the sleeve 22. In certain embodiments, core 230 is molded by injecting a UV curable material into the mold, and mold parts 400a, 400b are made of a UV transmitting material (i.e., Teflon) in such a way that light / UV radiation can be transmitted through mold pieces 400a, 400b to cure core 230 within the mold.

Referring again to Fig. 15, core 230 is shaped io to include a flange 260 that engages spring 228. In addition, core 230 is configured to support trailing end 28 of socket 22 within the connector element 204. Furthermore, a leading end or flange 263 of the core 230 is configured to engage a protrusion 261 within the connector element 204 to stop the forward movement of the bushing assembly 20 caused by the direct shunt provided by the spring 228. From this In this way, the flange 263 functions to retain the sleeve 22 inside the element of the connector 202. Figure 25 shows the bushing assembly 20 after the core 230 has been over-molded on the rear end 28 of the bushing 22, on the splice location 218 and on a buffered portion of the fiber optic 216 of the fiber optic cable 212 . Step 312 of Figure 16 is representative of the completed molding operations.

In certain embodiments, core 230 may be made of a thermoplastic material, a thermoset material (a material in which crosslinking was established during heat cure), other types of crosslinked materials, or other materials. Example materials include acrylates, epoxies, urethanes, silicones, and other materials. At least some of the materials may be UV curable (ie the materials cure when exposed to UV radiation / light). As described above, in certain embodiments, an injection molding process (i.e., a thermoplastic injection molding process) can be used to apply and form core 230 over splice location 218 and bushing 22. In In certain embodiments, a hot melt material can be injected into the mold to form the core 230. io The use of hot-melt materials (i.e., hot-melt thermoplastic materials) and / or UV-curable materials enables the core overmolding process to be carried out at relatively low pressures (i.e., less than 1000 pounds per square inch (Ippc)) and at relatively low temperatures (i.e. less than 300 degrees Celsius). In some examples, curing can take place at temperatures of less than 200 degrees Celsius, or less than 100 degrees Celsius, or at room temperature, and at pressures below 100 Ippc or at pressures below 10 or 5 Ippc.

After the cores 230 have been over-molded at each end of the fiber optic cable 212, the other components of the fiber optic connectors 202 are assembled on the bushing assembly 20 and the core 230 (see step 314 in Figure 16). Additionally, the reinforcing members of fiber optic cable 212 are attached to the rear ends of connector elements 204 of fiber optic connectors 202. A continuity inspection can be carried out so that the switching cables and dust caps are placed on the bushings 22 (see step 316 in Figure 16). Finally, the switch cords are packaged and labeled (see step 318 of Figure 16). It will be appreciated that any and / or all steps of manufacturing the above connectors can be automated. Robotic systems can improve the consistency and quality of the connectorization process, and automation can help reduce labor costs.

Various additional fiber optic connector modalities are described below. It will be appreciated that the various materials, properties, dimensions and other characteristics described above with respect to components such as the socket, the optical fibers, the core, the connector element and the sheath are also applicable as similar components, they are described to continuation.

Figures 26, 27 and 27A illustrate another fiber optic cable and connector assembly 200a in accordance with the principles of the present disclosure. The fiber optic cable assembly and connector 200a includes a fiber optic connector 202a having a connector element 204a in which a socket 22a is mounted. Ferrule 22a supports a fiber optic end cap 24a having a bare fiber optic segment 46a spliced ​​to a bare fiber segment 291a 216a of an optical fiber 216a of an optical cable. The fiber optic 216a includes a coated portion 293a. A loose buffer tube 221a that surrounds and protects at least a portion of the coated portion 293a of the optical fiber 216a. The bare fiber segment 46a is spliced ​​to the bare fiber segment 291a at a splice location 218a. A generally cylindrical protection layer 232a is coated or over-molded over splice location 218a. More specifically, protection layer 232a is shown extending from a rear end of bushing 22a to a front end of buffer tube 221a. Shielding layer 232a fully encapsulates bare fiber segments 46a, 291a, and also encapsulates a portion of a coated fiber segment 48a of fiber optic terminal end 24a and a portion of coated portion 293a of optical fiber 216a. The protective layer 232a further encapsulates the front end of the loose damping tube 221a. In certain embodiments, a portion of the material that forms the protective layer 232a flows around the exterior of the buffer tube 221a and also flows into the interior of the buffer tube 221a between the interior of the buffer tube 221a and the coated portion 293a of the fiber optic 216a. A core 230a is over-molded around the rear end of bushing 22 and encapsulates and protects shield layer 232a, as well as splice location 218a within shield layer 232a. Core 230a is attached or otherwise attached to bushing 22a. A spring 228a bypasses the socket core 230a and the socket 222a in a forward direction. As shown in Figure 27, the core 232a extends from the rear end of the sleeve 22a to the loose damping tube 221a and completely encapsulates the protective layer 232a. Furthermore, a rear portion of the core 232a surrounds and adheres to an outer surface of the buffer tube 221a to prevent the buffer tube 221a from being removed from the connector. Because both the protective layer 232a and the core 230a are coupled or otherwise attached to the buffer tube 221a, the buffer tube 221a has improved the sliding characteristics. Such characteristics are further enhanced if the protective layer 232a is attached to both the exterior and interior of the damping tube 221a.

In the embodiment of Figure 27, the portion of the core 230a attached to the outer surface of the buffer tube 221a has an axial length that is longer than a corresponding axial length of the portion of the protective layer 232a that is attached to the damping tube 221a. Figures 28, 29, and 29A show another fiber optic cable and connector 200b assembly that has the same basic construction as the fiber optic cable and connector 200a assembly, except for a protective layer 232b that has been lengthened to increase length. The contact layer 232b and a buffer tube 221b, and a core 230b have been modified to accommodate the elongated protection layer 232b. In this way, the portion of the shield layer 232b attached to the buffer tube 221b is longer than the portion of the core 232b that engages and is attached to or coupled to the buffer tube 221b. The embodiment of Figures 28, 29 and 29a is particularly advantageous for applications where the protective layer 232 has better adhesion characteristics with respect to the buffer tube 221 compared to the core material 230b. In contrast, the embodiment of Figures 27, 28 and 28A is preferred for embodiments in which the core material 230a has improved the adhesion characteristics with respect to the buffer tube 221a compared to the material of the protective layer 232a. In both embodiments, the rear portion of the core engages and circumferentially surrounds (ie, counter-interrupts) the damping tube.

Figures 30, 31 and 31A further show a fiber optic cable and connector assembly 200c in accordance with the principles of the present disclosure. The fiber optic cable and connector assembly 200c has a structure adapted to improve retention of a buffer tube 221c within a fiber optic connector 202c. As shown in Figures 31 and 31A, the fiber optic connector 202c includes a mechanically fitted crimp ring 295 adjacent a leading end of the buffer tube 221c. The crimp ring 295 includes a recess or receptacle in the form of an annular groove 296 that extends around a perimeter of the crimp ring 295. Fiber optic connector 202c further includes an over-molded core 230c on crimp ring 295 and the front end of buffer tube 221c. The core 230c includes an annular projection 297 which projects radially inward into the annular groove 296 of the clamp ring 295. Thus, there is a mechanical engagement between the core 230c and the clamp ring 295. The mechanical engagement resists relative axial movement between the clamp ring 295. The clamp ring has a leading end abutting against a shield layer 232c that protects a splice location 218c between a fiber optic termination 24c and a fiber optic 216. The fiber optic end cap 24c has front ends supported by a socket 22c and rear end portions projecting back from the socket 22c. Fiber optic 216c corresponds to a fiber optic cable. Protective layer 232c protects a bare fiber segment 291C and a coated portion 293C of that of optical fiber 216c, as well as a coated fiber segment 48c and a bare fiber segment 46c of the end cable of optical fiber 24c. Core 230c surrounds and is coupled to (i.e. nested at, attached to, attached to) a rear end of bushing 22c and completely encloses shield layer 232c, front end of buffer tube 221c, and crimp ring 295 A rear end of shaft 230c forms a contact surface io of the annular damping tube which prevents the entry of an outer element of the damping tube 221c at a rear location of the crimping ring.

295.

In the embodiments of Figures 27, 29, and 31, the cores have rear portions that circumferentially engage their corresponding damping tubes. Therefore, the molds used to form the cores prevent entry into the buffer tubes. In contrast, Figures 32, 33 and 33a further show a fiber optic cable and connector assembly 200d in accordance with the principles of the present disclosure where a core 230d of a fiber optic connector 202d does not engage a corresponding buffer tube 221 d of fiber optic cable assembly and 200d connector. Instead, the fiber optic cable and connector assembly 200d includes an elongated shield layer 232d that encapsulates a front end of buffer tube 221d and also encapsulates the location of mpalme 218d. Protection layer 232d defines an annular groove 298 that extends around its perimeter at a location adjacent to splice location 218d. The core 230d is over-molded onto the protective layer 232d and includes an annular projection 299 that fills and fits within the annular groove 298. In this way, a mechanical mesh is formed between the protective layer 232d and the core 230d. to avoid relative axial movement between core 230d and protection layer 232d. The protective layer 232d is preferably attached or otherwise attached to the outer surface of the buffer tube 221 d and may also fill a portion of the buffer tube 221d in order to io connect to an inner surface of the buffer tube 221 d. Protection layer 232d projects back past a rear end of core 230d. In this way, the rear end of the core 230d circumferentially surrounds and contacts the protection layer 232d, but does not contact the buffer tube 221d. Therefore, a mold for forming the core 230d is configured to prevent entry around the protective layer 232d instead of the buffer tube 221d. In other embodiments more than one interior locking structure can be provided between the core 230d and the protection layer 232d. Furthermore, the interior locking structures can be provided at different locations along the length of the protective layer 232d. Protection layer 232d has an outside diameter greater than the outside diameter of buffer tube 221 d.

Figures 34, 35 and 35a show another fiber optic cable assembly and connector 200e in accordance with the principles of the present disclosure. The fiber optic cable assembly and connector 200e includes a fiber optic connector 202e with a ferrule 22e that supports a fiber optic terminal end 24e. The fiber optic cable and connector 200e assembly also includes a fiber optic 216e spliced ​​to the end of the fiber optic 24e at the splice location 218e. Optical fiber 216 corresponds to an optical cable having a damping tube 221 e. The fiber optic end cap 24e includes a coated fiber segment 48e and a bare fiber segment 46c (ie, a bare glass segment). Optical fiber 216 includes a bare fiber segment 291e and a coated portion 293e. A protective layer 232e extends from a rear end of bushing 22e to a front end of buffer tube 221 e. In the depicted embodiment, protection layer 232 is generally cylindrical and has a maximum outside diameter that is smaller than an inside diameter of buffer tube 221 e. Protective layer 232e protects splice location 218E and bare fiber segments

46e and 291 e. Protection layer 232e also encapsulates portions of coated fiber segments 48e and coated portion 293e. A core 230e is over-molded on the rear end of the bushing 22e, and on the front end of the damping tube 221 e. Protection layer 232e is completely closed or encapsulated within core 230e. A mold used to form core 230e is closed on buffer tube 221e. In this way, the rear portion of the core 230e circumferentially surrounds and is fixed to an outer surface of the damping tube 221 e. A front portion of the core 230e circumferentially surrounds and engages the rear end of the socket 22e.

Figures 36-40 show a sequence for the splice of a fiber optic termination cable 24f supported by a sleeve 22f to an optical fiber 216f of a fiber optic cable. The fiber optic end cap 24f includes a bare fiber segment 46f and a coated fiber segment 48f. Fiber optic 216f includes a bare fiber segment 291f and a coated portion 293f. The fiber optic cable also includes a buffer tube 221f that surrounds the clad portion 293f of the fiber optic 216f. Figure 36 shows the io fiber optic 216f coaxially aligned with the fiber optic terminal 24f in the splice preparation. Figure 37 shows the fiber optic termination cable 24f spliced ​​to the fiber optic 216f. Figure 38 shows an over-molded or otherwise applied protection layer 232f over a splice location 218f between fiber optic 216f and fiber optic termination 24f. Protective layer 232f extends from a rear end of bushing 22f to a front end of buffer tube 221f. Fig. 39 shows a core frame 300 (i.e., a box or frame) mounted on the rear end of the bush 22f and the front end of the protective layer 232f. Core shell 300 is preferably a preformed part that can be inserted into socket 22f. In certain embodiments, the core shell 300 is made of a relatively hard plastic material such as a polyamide material. As shown in Figure 39, the core frame 300 includes a front ring 302 that is mounted on the socket 22f and a rear ring 304 located on the protective layer 232f. A plurality of axial flanges 306 connect the front ring 302 to the rear ring 304. An inside diameter of the front ring 302 preferably closely matches the size of the outer diameter of the bushing 22f. A front end of the front ring 302 can include a plurality of oblique surfaces 308 adapted to be within a connector element when the mounting is bypassed by the spring to a front position within a connector. A plurality of openings 310 are defined between axial flanges 206. For example, in the embodiment depicted, two axial flanges 206 spaced io about 180 ° from each other are disposed between the front and rear rings 302, 304. In other embodiments, more than two axial flanges 306 may be provided. Back ring 304 has an inside diameter that is substantially larger than an outside diameter of protection layer 232f. In this way, an annular crack 312 is defined between the inner surface of the back ring 304 and the outer surface of the protective layer 232f. Core shell 300 may be made of a material that is harder and more robust than the material used to form a posterior portion of the core. The core shell 300 may be over-molded onto the sleeve 22f and may include an inner portion that fills or fits within a groove / cavity 23f of the sleeve 22f to improve retention of the core shell 300 in the socket 22f. Core shell 300 can be over-molded using an overdrive process that has higher process temperatures and pressures than in a molding process used to form a core portion (ie core portion 314) that covers the core. splice location. In this way, the core is provided with a robust construction without exposing the joint location to processing temperatures and high pressures.

After the core shell 300 has been mounted on the bushing 22f as shown in Figure 39, a portion of the over-molded core 314 can be over-molded in and on the core frame 300 to form a composite core 230f that is coupled to socket 22f and contains junction location 218f. The over-molded portion 314 preferably fills the empty regions between the axial flanges 306 and also fills the annular gap 312 between the back ring 304 and the protective layer 232f. In the embodiment shown, the over-molded core portion 314 completely encapsulates the protective layer 232f and includes a rear portion that closes around the buffer tube 221f. Core shell 300 and over-molded core portion 314 cooperate to define the composite core

230f which is anchored to socket 22f. The portion of the over-molded core flowed into the cracks between the annular flanges 306 of the core frame 300 ys attached to an outer surface of the sleeve and functions to lock the core frame 300 in place relative to the ferrule 22f. The axial flanges 306s are shown embedded within the overcast core portion 314 and a portion of the overcast core portion forms a ring 316 surrounding the axial flanges 306. The ring 316 abuts against a rear of the front ring 302. and has an outer surface which is generally discharged with an outer surface of the front ring 302. The front end of the front ring 302 is not covered by the over-molded part 314. In this way, the front end of the front ring 302 forms a front nose of the composite core 230f.

It will be appreciated that the composite core 230f can be used in any of the fiber optic connectors in accordance with the principles of the present disclosure. Furthermore, in certain embodiments, the overcast core portion 314 is formed from a heat-melt adhesive or other material that can be applied and cured at relatively low molding temperatures and pressures. In certain embodiments, the overcast core portion 314 is made of a material that has different material properties than the core shell material 300. For example, the overcast core portion 314 may be softer or stronger. than the core fragment 300. The composite nature of the core 230f simplifies the molding operation.

The composite construction of composite core 230f relies on core fragment 300 to provide mechanical strength and precision. The composite construction of the composite core 230f is based on the over-molded core portion 314 for attachment of the composite core 230f to the bushing 22f, for attachment of the composite core 230f to the damping tube 221f, and to provide additional protection from location splicing

218f and the bare fiber segments 46f, 291f.

It will be appreciated that various aspects of the present disclosure are also applicable to multi-fiber connectors. For example, Figure 41 shows a multi-fiber bushing 422 supporting a plurality of fiber optic termination straps having a plurality of fiber optics 424. Bushing 422 may include openings 427 into which the alignment pins can be mounted to configure the bushing 422 as a male component. The optical fibers 424 are preferably aligned along a row within the bushing 422 and have end faces that are polished and accessible at a front end 426 of the bushing 422. The rear portions 438 of the optical fibers 424 extend, backwards from a rear end 428 of bushing 422. Similar to the above embodiments, the optical fibers 424 may be precision optical fibers having different properties or characteristics than the optical fibers of the fiber optic cable to which the fiber optic termination end is to be spliced.

In certain embodiments, the optical fibers 424 of the fiber optic terminal end are spliced ​​to the optical fibers of the cable at a location close to that of the rear 428 of the sleeve 422. For example, in one embodiment, the splice location is within 10 millimeters of trailing end 428 of bushing 422. In other embodiments, the splice location is within 5 millimeters of trailing end 428 of bushing 422. In still other embodiments, the splice location is in the range of 2-5 millimeters from trailing end 428 of bushing 422.

Figure 42 shows bushing 422 mounted within a multi-fiber fiber optic connector 430. Connector 430 Includes a connector element 432 has a front piece 432a and a rear piece 432b. A sleeve 434 is mounted to a rear end of rear piece 432b of connector lug 432. Front end 426 of bushing 422 is accessible at the front end of connector element 432. A removable dust cap 435 is shown mounted on the front end 426 of bushing 422. A release sleeve 437 is mounted on connector element 432. A spring 439 bypasses bushing 422 in a forward direction. To use the 430 fiber optic connector, the 435 dust cap is removed thus allowing the front end of the connector to be inserted into a corresponding fiber optic adapter (for example, an MPO adapter). As is known in the art, fiber optic connector 430 (eg, an MPO connector) fits within the fiber to optical adapter. By pulling back on the 437 release sleeve, the fiber optic connector

430 It can be released from the fiber optic adapter.

Figures 43-48 show a sequence of steps for the preparation of a multifiber fiber optic cable 440 to be spliced ​​to the optical fibers 424 of the ferrule 422 of Figure 41. The multifiber cable 440 can include a plurality of positioned optical fibers 442 within an envelope 444. A resistance layer 446 to provide tensile reinforcement to cable 440 may be placed between the envelope 444 and the optical fibers 442. In certain embodiments, resistance layer 446 is made of a tensile reinforcing material such as aramid yarn.

As shown in Figure 43, the outer jacket 444 has been peeled away to expose about 25-35 millimeters of the optical fibers 442. The resistance layer 446 is shown separated from the fibers 442 and folded back onto the jacket 444. The optical fibers 442 have been arranged and arranged in a row. A material such as a tape 448 can be used to keep the coated optical fibers 442 in the desired order. In the embodiment depicted, the optical fibers 442 include twelve fibers arranged in a flat 12x1 matrix. In other embodiments, other types of instant adhesive can be used to secure optical pounds 442 in the desired order sequence.

Figure 44 shows resistance layer 446 trimmed to a length suitable for attachment to multi-fiber connector 430. In one embodiment, resistance layer 446 is trimmed to a length of approximately 4-6 millimeters.

Figure 45 shows an overcast section of thermoplastic 450 being molded onto ordered optical fibers 442. In one embodiment, overcast section 450 is separated from cable sheath 444 by a distance d1 in the range of about 9 -13 millimeters. In certain embodiments, the overcast section 450 has a length d2 of approximately 3-6 millimeters. In certain embodiments, d1 can equal approximately 11 millimeters and d2 can equal approximately 4.5 millimeters.

Figure 46 shows the spring 439 of the multifiber connector 430 inserted over the optical fibers 442 of the cable 440. Figure 47 shows the coatings of the optical fibers 442 separated from the optical fibers 442. In this way, the bare glass portions of the fiber optics 442 are exposed. In certain embodiments, the bare glass portions may start at a separate point at a distance d3 of approximately 15-17 millimeters from the end of the cable sheath 444. After the separation step, the bare optical fibers may be cleaned and inspected for defects.

Figure 48 shows the optical fibers 442 after the optical fibers 442 have been cleaved (eg, cleaved laser). In certain embodiments, after cleavage, the bare fiber portions of the optical fibers 442 have a length d4 of approximately 5 millimeters. After cleavage, the fiber optic cable 440 is ready to be spliced ​​to the fiber optics 424 with the support of the multi-fiber bushing 422.

The assembly of the multi-fiber bushing 422 and the optical fibers 424 is shown in Figure 49. To access the assembly shown, the bushing 422 can be fed by bowl and collected and placed at the outlet of the bowl. It will be appreciated that the front end 426 of the bushing 422 has been pre-processed and the end faces of the optical fibers 424 at the front end 426 have been pre-polished. Furthermore, in the bowl, the end face 426 is preferably protected by a dust cap. An automated system can scan and read the information provided on bushing 422 (or on the dust cap) that identifies bushing 422. The automated system can also remove the full dust cap, rotate cap 422 in a vision system to precisely find the window in the cap, and can precisely position the cap in a clamp / holder, without touching or damage front face 426 of bushing 422.

Figures 50 and 51 show the steps for preparing the optical fibers 424 of the multi-fiber bushing 422 for splicing the optical fibers of the multi-fiber cable 440 For preparing the bushing 422 and the optical fibers 424 for splicing, the coatings of the optical fibers 424 are separated to expose bare glass portions of the optical fibers 424 as shown in Figure 50. In addition, the optical fibers can be cleaned and examined for defects. As shown in Figure 51, the bare optical fibers are then divided to a length d5 ​​of, preferably, 5 millimeters or less.

As shown in Figure 51, the damped portions of the optical fibers project outward from the rear side of the bushing 422 for a distance of less than about 1 millimeter. In the illustrated embodiment of Figure 51, a sheath 450 is shown schematically located within socket 422 adjacent rear end 428. The sheath 450 is configured io to provide radius of curvature and strain relief protection to the optical fibers 424 adjacent the rear end 428 of the bushing 422. Preferably, the sheath 450 projects no more than 2 millimeters, rearward, from the trailing end 428 of bushing 422. In other embodiments, the rear end of the sleeve 450 can be recessed into the socket 422, so that it travels forward from the rear end 428 of the socket. In this way, sheath 450 provides protection of optical fibers 424 without interfering with subsequent splicing operations taking place near the rear end 428 of bushing 422.

Figure 52 shows the optic fibers of end cap 424 of the ferrule.

422 the fusion being spliced ​​to the optical fibers 442 of the multifiber cable 440.

A fusion splice tray 600 is used to provide alignment of the optical fibers 442, 424 and to protect the various components from exposure to the fusion splice arc. The tray has a length L, a width W, and a height H. The width W extends in a direction parallel to the optical fibers 442, 424 when the optical fibers 442, 424 are supported in the tray 600. As shown in Figure 53, when viewed in a top plan view, tray 600 has a tapered, waist region 602 (i.e., a tapered, waist region) at an intermediate location along length L The narrow, waist region 602 has a reduced width W1 that is smaller than the width w of tray 600 at the ends of tray 600. Narrow region 602 is provided by notches 603 that extend into a main body of tray 600 on opposite sides of tray 600. In other embodiments, only one of the notches can be provided to form the narrowed region 602.

Narrowed region 602 corresponds to a splice region / zone 613 where optical fibers 442, 424 are routed through tray 600 and spliced ​​fusion together. Alignment structures in the form of V-grooves

604 are provided on an upper side of the tray 600 adjacent the tapered region 602 to support the optical fibers 442, 424 and to coaxially align the optical fibers 442, 424. In other embodiments, the active alignment kit of the type described above, can also be used to coaxially align optical fibers. Narrowed region 602 provides clearance to allow optical fibers 442 to splice to optical fibers 424 in proximity to trailing end 428 of bushing 422.

Tray 600 also includes a structure to prevent debris from contaminating splice region 613. As shown in Figures 52 and 53, the arc / fusion splice 610 fits within a groove 612 that runs the length of the length L of the tray 600. The slot 612 tapers to a narrowed portion 615, as the slot passes into the region where the V-grooves 604 support the optical fibers 442, 424. The tapered portion 615 corresponds to the splice region 613. The electrodes 610 are located on opposite sides of the splice region 613 of the tray 600. The free ends of the optical fibers 442, 424 that are intended to be spliced ​​together protrude the tapered portion 615 of slot 612. Contamination reduction slots 616 are positioned adjacent to each of the V-slot assemblies 604. Specifically, the contamination reduction grooves 616 are positioned between the V grooves 604 and the tapered portion 165 of the groove 612. Preferably, the contamination reduction grooves 616 extend entirely through the height H of the tray. 600 and allows contamination to fall through tray 600 instead of contaminating the ends of the fibers prior to splicing. The rails 618 are positioned between the contamination reduction grooves 616 and the narrowed portion 615 of the groove 612. The rails 618 are preferably slightly undercut with respect to the depth of the V grooves 604. For example, as shown In Figure 54a, the top sides 620 of rail 16 are positioned lower than valleys 622 of V-grooves 604. It will be appreciated that the depth of slot 612 extends substantially below the top sides 620 of rails 618. Rails 618 operate to trap debris before debris enters slot 612.

Slot 612 is preferably deep enough for an electric arc to pass between electrodes 610 and used to heat and melt the ends of optical fibers 442, 424 together. By embedding electrode 610 into slot 612, the tray 600 works to protect bushing 422 and other components from the heat associated with the arc. Before the ends of the optical fibers are fused together with one another through the arc generated between the electrodes 610, a short burst of electric arc can be used to clean the splice area. The V-grooves can be defined in a ceramic portion of the tray 600 (or the tray can be made entirely of ceramic materials or the like) and can be used to provide the final alignment of the optical fibers 442, 424. Tray 600 can also protect areas outside of the splice area from unwanted exposure to arc flash. The arc provided between electrode 610 readjusts the glass of the optical fibers, and therefore provides a splice therebetween. In other embodiments, alternative heat sources can also be used.

After the fusion splicing process is complete, the components are removed from tray 600 and the fusion splice area s, preferably, over-molded with a protective coating material such as an ultraviolet cured polymer. The ultraviolet cured polymer is preferably cured to ensure it is stable at temperatures above 100⁰ C. The socket 422 is then configured to be a female component (see Figure 56) or a male component (see Figure 57). A spring clip can be mounted adjacent to the rear side of the socket, as needed, for either the female or male plug configuration.

Subsequently, the bushing 424 and the spring are loaded into the front part 432a of the connect housing 432 (see Figure 58) and the rear part 432b of the connect housing 432 is fixed to the front portion 432a, thereby retaining the spring and bush on it (see Figure 59). Then, the resistance layer 446 of cable 440 is secured (eg, crimped with crimp ring 460) to a terminal line 462 of rear portion 432b of connector housing 432 (see Figures 59 and 60). Next, the 434 sleeve is installed over the crimp band, as shown in Figure 61, and the 435 dust cap is installed over the front end of connect 430 as shown in Figure 62.

Figures 63-67 show a sequence for splicing a 24g fiber optic termination supported by a bushing 22g to a 216g fiber optic of a fiber optic cable. The 24g fiber optic termination line includes a 46g bare fiber segment and a 48g coated fiber segment. Fiber Optic 216g Includes a bare fiber segment 291g and a coated portion 293g. The fiber optic cable also includes a buffer tube 221g that surrounds the clad portion 293g of the fiber optic 216g. Figure 63 shows fiber optic 216g coaxially aligned with fiber optic terminal 24g in preparation for splicing. Figure 64 shows the 24g fiber optic termination splice to the 216g fiber optic. Figure 65 shows a protective over-molded layer 232g or otherwise applied over a splice location 218g between fiber optic 216g and fiber optic end cap 24g. Protective layer 232g extends from a rear end of bushing 22g to a front end of buffer tube 221g. FIG. 66 shows a body 500 having a front core portion 502 and a rear core portion 504. Front core portion 502 includes flat sides 506 and an interlock portion 508, such as a dovetail. In certain embodiments, the front core portion 502 of the body 500 can be made of a relatively hard plastic material such as a polyamide material. As shown in Figure 66, the front core portion 502 is pre-molded (eg io overmolded) on the bushing 22g before the termination end of the fiber optic 24g which is spliced ​​to the fiber optic 216g. The marking can be placed on the flat sides 506 of the front core portion 502 to aid in adjustment. In certain embodiments, the front core portion 502 has 6 or 8 floors. The floor 506 closest to the direction of core travel may be marked for later identification when the 22g bushing assembly is loaded into a connector element. Therefore, the floor marked 506 can be used to identify (either manually or automatically) the direction of the displacement core of the bushing 22g.

After the front core portion 502 has been molded onto the sleeve 22g and the fibers 24g, 216g have been spliced ​​together, as shown in Figure 64, the rear core portion 504 can be over-molded into and onto the portion of front core 502 to form a composite core 230g that is coupled to the socket 22g and contains the splice location 218g. The rear core portion 504 is over-molded to encapsulate the dovetail of the front core portion 502 and the protective layer 232g. In the embodiment depicted, the rear core portion 504 fully encapsulates the protective layer 232g and includes a rear portion that closes around the buffer tube 221g. The front end of the front core portion 502 is not covered by the rear core portion 504. In this way, the front end of the front core portion 502 forms a front nose of the composite core 230g. Figure 67 shows an alternative embodiment of the posterior core portion 504. Referring to Figure 68, the bushing 22g is shown without the posterior core portion 504 and the damping tube 221g removed. Figures 69-70 are side and cross-sectional views of Figure 68. Figure 71 is a top view of Figure 69, and Figure 72 is a perspective view of the alternative embodiment. Figures 73-74 are side and cross-sectional views of Figure 72.

It will be appreciated that the 230g composite core can be used in any of the fiber optic connectors in accordance with the principles of the present disclosure. Additionally, in certain embodiments, the rear core portion 504 is formed from a heat-melt adhesive that can be applied and cured at relatively low molding temperatures and pressures. The rear core portion 504 may also be formed of a UV curable material (ie, the materials cure when exposed to radiation / ultraviolet light), for example, UV curable acrylates, such as OPTOCAST ™ 3761 manufactured by

Electronic Materials, Inc. of Breckenridge, Colorado; ULTRA LIGHT-WELD® 3099 manufactured by Dymax Corporation of Torrington, Connecticut; and 3M ™ SCOTCH-WELD ™ manufactured by 3M of Saint Paul, Minnesota. The use of UV curable materials is advantageous in that curing can occur at room temperature and generally lower pressures (eg, less than 30 kpsi, and generally between 20-30 kpsi). The availability of low pressure curing helps to ensure that components, such as the optical fiber (s), being over-molded are not damaged during the molding process. In certain embodiments, an injection molding process can be used to apply and / or form the rear core portion 504 of a UV curable material on the protective layer 232g and the front core portion 502. In certain embodiments, the rear core portion 504 is made of a material that has different material properties than the material of the front core portion 502. For example, the rear core portion 504 may be softer or stronger than the front core portion 502. The composite nature of the core 230g simplifies the molding operation. The front core portion 502 can be over-molded using an over-molding process that has higher temperatures and pressures than the over-molding process used to form the rear core portion 504. The front core portion can interlock with the bushing 22g.

In some embodiments, the composite construction of the 230g composite core relies on the front core portion 502 to provide mechanical strength and precision, and for attachment of the 230g composite core to the 22g bushing (e.g., the front core portion 502 is attached to socket 22g). In some embodiments, the composite core 230g composite construction relies on the rear core portion 504 for attachment of the composite core 230g to the buffer tube 221g and to provide additional protection from splice location 218g and fiber segments nude 46g, 291g.

In one embodiment, the front core portion 504 may be mounted (eg, over-molded) on the socket 22g prior to polishing, cleaning, cleaving, separating, adjusting, active alignment, and splicing of the socket assembly. In this way, the front core portion 504 can be used to facilitate manipulation and positioning of the sleeve 22g during the various processing steps. In one example, a floor of the front core portion 504 may be marked for fit purposes.

In one embodiment, the rear core portion 504 may be over molded to encapsulate the dovetail of the front core portion 502 and the protective layer 232g in an injection mold assembly 700, as shown in Figures 75- 81. As shown, mold mount 700 includes an upper mold mount 702 and a lower mold mount 704. The upper mold assembly 702 includes an upper mold block 706 attached to, and operated by, the mold assembly 700 through an upper frame piece 708. Also, the lower mold assembly 704 includes a lower mold block 710 attached a, and operated by mold assembly 700 through a lower frame part 712. The actuation of the frame parts 708, 712 can be manual or automatic.

In one embodiment, the upper and lower mold blocks 706, 710 are formed of a UV light transmitting material, such as Dupont ™ TEFLON®

FEP 100 Fluoropolymer Resin. This material has been found to have sufficient UV light transmission characteristics above 300nm wavelengths at thicknesses corresponding to those used for 706, 710 mold blocks (eg, approximately 50-75% transmissivity for thicknesses of material between 1-2 millimeters in UV wavelengths of 365 nm at or an initial intensity of approximately 1.7 to 2.0 watts / square centimeter). Furthermore, TEFLON® has beneficial properties that allow mold blocks 706, 710 to be molded into complex mold cavity shapes, as well as being resistant to adhesion to the cured material in the mold cavities. This material also allows mold blocks 706, 710 to have mating surfaces that are sufficiently formed to prevent unwanted flickering in the molded part.

The upper mold block 706 and the lower mold block 710 may have a plurality of cooperating the cavity portions 714, 716 to form the rear core portion 504. As can be seen more readily in the

Figures 80-81, the upper mold block 706 has an upper cavity portion 714 that cooperates with a lower cavity portion 716 in the lower mold block 710. As shown, the upper cavity portion 714 includes a mold cavity portion 714a, a gland clamping portion 714b, and a buffer tube cavity portion 714c while the lower cavity portion 716 includes a cavity portion of the mold 716a, a socket clamping portion 716b, and a buffer tube cavity portion 716C. When the upper and lower mold blocks 706,

710 are pressed against each other through the operation of the frame parts 708, 712, the upper and lower cavity portions 714, 716 form a mold cavity with portions 714a, 716a, and secure the bushing 22g with portions 714b, 716B. The buffer tube cavities 714c, 716C create a passage for a buffer tube 221g during the molding process.

It is noted that mold blocks 706, 710 may include upper and lower vacuum channels 724, 726, connected to a vacuum source (not shown), to fix the bushes 22g against the portions 714b, 716B to prevent unwanted movement during the molding process. As shown, channels 724, 726 extend along mold blocks 706, 710 to each of cavity portions 714b, 716B. It is further observed that the contours of the mold cavity portions 714a, 716a coincide with the shape of the fully formed posterior core part 504 shown in Figures 67 and 72-74. In the embodiment shown in Figures 75-79, there are twelve pairs of cooperating mold cavity portions 714, 716 such that twelve posterior core portions 504 can be formed, simultaneously, by the mold assembly 700.

As shown, the mold assembly 700 further includes a series of injection needles 718. In one embodiment, there is an injection needle 718 for each mold cavity. However, more than one injection needle can be provided for each mold cavity. Injection needles 718 are for injecting the uncured material for the rear core portion 504 into the mold cavities formed after the mold blocks 706, 710 have been pressed against each other. In one embodiment, lower mold block 710 includes passages 752 that provide a fluid communication path between injection needles 718 and corresponding mold cavities. It is noted that the injection needles 718 can be made of a material that is not transmissive to UV light, such as a metal, in order to prevent unwanted or premature curing within the injection needle 718.

Referring to Figures 78-79, a valve 720 is provided having a passage 722 within passage 752 of the lower mold block 710.

In one embodiment, valve 720 is made of a material that is not UV transmissive, such as opaque silicone or EPDM rubber. Such material will help prevent the uncured material within valve 720 and / or injection needle 718 from being undesirably cured during the molding process. In one embodiment, valve 720 is configured as a one-way valve such that uncured material can flow into the mold cavity through passageway 722, but cannot flow from the mold cavity back to the injection needle

718.

In one embodiment, valve 720 is made of a flexible polymeric material and is configured such that passage 722 opens when a pressure threshold exerted by the uncured material within injection needle 718 is exceeded, and closes when the pressure is lowered enough. In one embodiment, valve 720 is a slit-type valve. It is noted that Figures 78-79 show valve 720 in an open position with passage 722 shown oversized for clarity. The combined features of valve 720 also result in the molded back core portion 504 that is free of the legs or runners that will not normally need to be removed from a molded product after the molding process.

Additionally, each injection needle 718 may be configured to be inserted through its respective valve 720 and into cavity area 716a, 714a by injecting the molding material into the cavities. In such a configuration, the injection needles 718 can be retracted from the mold cavities after the cavities are sufficiently full and before the curing process begins. It is also noted that the mold assembly 700 can also be configured to draw a slight vacuum in the uncured material within the injection needles 718 after filling the mold cavity to help ensure that the uncured material is removed, more away from the UV light exposure area.

As shown, mold mount 700 further includes a plurality of UV 728 lamps (728A, 728B, 728C). UV lamps 728 are found to direct UV light toward mold cavity portions 714b, 716B, so that UV sensitive material within the cavities can be cured during the molding process. In the embodiment shown, three UV lights are arranged to direct the UV light into each mold cavity from various angles. It is observed that more or less UV lights could be used. In the embodiment shown, UV 728 lamps include LED bulbs that emit 365 nanometer (nm) ultraviolet light at 3 watts per square centimeter. It is noted that other wavelengths and intensities can be used, and that the chosen wavelength and the intensity of the lights are generally a function of the selected materials used for the mold blocks and the posterior core portion 504 . Referring to Figure 75, a total of 14 sets of UV lamps 728a, 728b, 728C are provided for the twelve mold cavities. While the 12 assemblies directly expose light into a particular mold cavity, an additional set of UV lamps is provided at each end of the mold blocks 706, 708 to ensure that the outermost mold cavities are exposed thereto. UV light level like Interior mold cavities.

As most easily seen in Figure 78, upper mold block 708 has a plurality of cavities 730 for receiving UV lights 728A. Lights

UV 728a are oriented to direct light down onto the upper cavity portion 714b. Lower mold block 710 has recesses 732 and 734 to receive UV lights 728b and 728C, respectively. The recesses 732 and 734 are angled due to the presence of the injection needles 718, the valves 720 and the ejection pins (discussed later). It is noted that since the 720 valves and 718 injection needles cannot transmit UV light, that the 728b and 728C UV lights must be oriented to ensure the mold cavity is sufficiently exposed to UV light around these components . As mentioned above, because mold blocks 706, 710 are UV light transmitting, UV lights are able to cure the molding material within the mold cavities while mold blocks 706, 710 are closed together .

Once the mold material has been sufficiently cured to form the rear core portions 504, the vacuum holding the bushings may be interrupted and the mold blocks 706, 710 may be separated. In order to facilitate removal of the composite core 230g from the mold blocks 706, 710, the mold assembly 700 may be provided with an ejector assembly 736. In one embodiment, the ejector assembly

736 includes an upper ejector assembly 738 located in the upper mold assembly 702 and a lower ejector assembly 740 in the lower mold assembly 704. As shown, each of the ejector assemblies 738, 740 includes a plurality of ejector pins 740 , 742 connected to a common support rail 744, 746. The number of ejector pins 738 corresponds to the number of mold cavities. Consequently, the upper mold block has a passage 748 for the ejector pins 740, while the lower mold block has a passage 750 for the ejector pins 742. To remove the core 230g from the mold blocks 706, 710, the ejector pins 740, 742 are driven in passages 748, 742 until they contact and dislodge the gland portion 22g located within the cavity portions 714b, 716B. Support rails 744, 746 that drive pins 740, 742 can be manually or automatically operated. It is observed that the ejection pins

740, 742 can be manufactured from a UV light transmitting material in order to minimize interference with the curing process. Examples of UV light transmitting materials for ejection pins 740, 742 are clear glass and polycarbonate. It was also observed that the ejector pins can be removed or partially retracted away from the cavities in the mold blocks 706, 710 during the curing process to reduce interference with UV light transmission.

Referring to Figure 82, an injection molding process 1000 is shown in which mold assembly 700 can be used to form an over-molded ferrule and composite core. In a first step 1002, bushings with pre-molded collars, which can be spliced ​​to damping fibers from cable assemblies, are placed over the cavities in the mold assembly. In a second stage 1004, a vacuum is activated to maintain the bushings and prevent unwanted movement in axial or rotational modes. It is observed that the vacuum can be active before the caps with the pre-molded collars are placed over the cavities. In a third step 1006, once all the desired cavities in the mold are filled, the mold blocks of the mold assembly are closed together. In another step 1008, the EFD or the like ss dispensing units are used to deliver the UV material into the mold cavities under low pressure through the injection needles and associated valves. The amount of material injected can be calculated or determined, empirically, using tests to optimize fill volume without causing unwanted flash or other protrusions.

In another 1010 step, the UV lights are activated and turned on at an intensity and duration optimized to fully cure materials with minimal cycle time. In one embodiment, the cycle time is approximately 10 seconds when using a 365 nm UV light at 3 watts per square centimeter. In one embodiment, the intensity of UV light is initially low, eg, for the first 5 seconds of a 10-second cycle, and then rises to a higher value. Such an approach is beneficial where the material to be cured may be sensitive to volatilization if it is initially exposed to the higher intensity value. In another step 1012, the mold blocks are separated. The ejector pins can also be used during separation η I instead of the bushing to dislodge the over-molded bushing and the core. In another step 1014, the over-molded bushing and core are removed from the mold assembly. It is noted that other injection molding applications can be used with the mold assembly and process described above, and that the disclosure is not limited to injection molding and components related to fiber optic technology.

Figures 83 and 84 show another bushing assembly 20h and core 230h in accordance with the principles of the present disclosure. Cap mount 20h includes a cap 22h that supports a fiber optic termination

24h. The 24h fiber optic termination end is fused spliced ​​to a fiber optic 216h of a fiber optic cable 212h at a splice location 218H. Core 230H mounts to the rear end of socket 22h and covers splice location 218H. Core 230h Includes a front core portion 502H and a rear core portion 504H. The rear core portion 504H includes an outer core shell 900 defining an inner cavity 902. The outer core shell 900 includes an axial / longitudinal groove 904 that allows the outer core shell 900 to be inserted, laterally, over the fiber optic terminal 24h and the fiber optic 216h at the location of joint 218H after that the 24h fiber optic end cable has been spliced ​​to the 216h fiber optic. The outer core shell 900 also includes a port 906 to allow the outer core shell 900 to be filled with an over-molded material (for example, a UV curable material, a heat-melt material, a thermoplastic material, a epoxy material, a thermosetting material, or other materials).

In-mold material 908 is not shown in Figures 83 and 84, but is depicted in Figure 93. Outer core housing 900 can function as a mold to shape the in-mold material 908 around splice location 218H, and along the lengths of the fiber optic cable 216h and the fiber optic terminal end 24h. A temporary mold piece can be used to cover the axial groove 904 while the overmold material 908 is injected into the outer core shell 900 through port 906. The shell

<img file="MX338237B_D0015.tif" />

Outer core 900 remains a permanent part of core 230h after material on mold 908 has been injected into it.

The front core portion 502H can be over-molded on the socket 22h or otherwise mounted on the socket 22h. The front core portion portions 502H may be meshed with grooves or other corresponding openings on the side of the bushing 22h to limit axial movement of the front core portion 502H relative to the bushing 22h. As shown in Figures 85 and 86, the front core portion 502H includes a front end 910 and a rear end 912. The rear end 912 is moved, toward the front, from a rear end 28h of the core 230h. In this way, the rear end 28h of the core 230h projects rearward from the rear end 912 of the front core portion 502h. In certain examples, the front core portion 502h is made of a hard material, stronger than the overmold material 908. In certain examples, the front core portion

502h may be over-molded in bushing 22h using an elevated temperature and / or a high pressure molding process compared &lt;j: on the molding process used to install overmould material 908 in the outer core housing 900. Still referring to Figures 85 and 86, the front core portion 502h may include a series of floors 914 used for indexing or otherwise rotationally positioning the socket assembly 20h in a connector such as the LC 990 connector of Figures 92 and 93. The front core portion 502h may also include front beveled sections 916 to seat the core or 230h within connector 990.

a material that is harder and more durable / robust than 908 overmold material in order to reinforce the rear core portion 504H and to protect and contain 908 overmold material. In the case where the overmold material 908 is UV curable, the outer core shell 900 can be made of a material that is transmissive to UV light, so that the overmold material 908 can be cured by transmission d light / UV radiation through the outer core shell 900.

Figures 87 and 88 show another bushing assembly 20i and hub 230i in accordance with the principles of the present disclosure. The 20i socket assembly and 230i core may have the same construction as the 20h socket and 230h core assembly except the 230i core including a 900i outer core housing having a 920 male end that fits into a 922 female receptacle defined on a rear side of a front core portion 502i. Male end 920 and female receptacle 922 may have complementary shapes. As shown, the male end 920 and the female receptacle 922 each include a series of floors that prevent relative rotation between the outer core housing 900i and the front core portion 502i. The male end 920 of the outer core shell is best shown in Figure 89.

Figure 90 further shows a bushing assembly 20j and core 230j in accordance with the principles of the present disclosure. The socket assembly 20j and the core 230j have the same basic configuration as the socket assembly 20h and the core 230h except that the core 230j includes a 900J outer core housing having a two-piece construction. The two pieces of outer core shell 900J are mated together with a splice location 218j captured from each other to form the outer core shell 900J.

Figure 91 shows an alternative 900k outer core shell that can be used with the socket assembly 20i and the front core portion 502i of Figures 87 and 88. The outer core shell 900k includes two half pieces of interlocking 950 which cooperate to define an internal chamber / cavity 902k to receive the overmold material. A port 906k for filling chamber / cavity 902k with overmold material is defined by at least one of the 950 mid pieces. The 950 half pieces cooperate to define a 920k male end to the front end of the outer core housing. 900k. Alignment features such as posts 956 and corresponding openings 958 ensure proper alignment between half pieces 950 and outer core shell 900k during assembly.

Figures 92 and 93 show connector 990 which includes the socket assembly 20h and the core 230h. The 990 connector includes a 991 main drive element that has a standard LC style form factor and mechanical interlocking arrangement. Connector 990 also includes a spring 992 to push socket assembly 20h and core 230h in a forward direction such that chamfered section 916 of core 230H sits within elemental main connector 991. The 990 connector also includes a rear housing

993 retaining the spring within the main body of connector 991. Connector 990 further includes a crimp 996 for attaching cable resistance elements to the back housing 993, and a sheath 998 to provide strain relief and bend radius control. the fiber at the cable-to-connector interface.

Although the ferrule assembly manufacturing process and the fiber optic cable and connector manufacturing process are preferred for both to be fully automated, it will be appreciated that certain steps in either process can be performed manually. Furthermore, while it is preferred for the cutting and splicing and processing technology described in this document to be used in a factory setting, such as technology and processing, it cannot also be used off-site in the field for applications of splice field (for example, at a customer location). In other words, fusion splicing, protection splicing, along molding, fixing of reinforcing member and mounting of the connector part or parts can be performed outside a factory, for example, at a site in the client. Also, while processing is described with respect to patch cords, it will be appreciated that the same processing technology can be used to connect a connector to any type of fiber optic cable. Furthermore, while SC connectors are shown, it will be appreciated that the technology is applicable to any type of fiber optic connector.

Another aspect of the present disclosure relates to a method of producing and distributing bulk fiber optic connector assemblies. A significant aspect of the method relates to centralized fabrication of large numbers of bushing assemblies, each having a bushing supporting a fiber end cap. In certain examples, the volume of bushing assemblies manufactured at a given centralized manufacturing location may exceed a volume of 500,000; 1,000,000; 2,000,000; or 3,000,000 bush assemblies. By manufacturing these large volumes of bushing assemblies in a centralized location, bushing assemblies can be done efficiently and a considerable capital investment can be made in manufacturing premium equipment and processes. For example, ferrule assemblies can be manufactured at a factory location using high-precision polishing technology and equipment. Furthermore, the high quality and precision bushings with io tolerances and auxiliary code fibers can be effectively matched to provide bushings with extremely high levels of optical performance. The large volumes of bushings assembled at a given central location provide the manufacturing efficiency for manufacturing this type of viable operation. Examples of such high quality manufacturing operations and equipment are described throughout this description. Centralized manufacturing also allows for substantial investment in automation.

The method also refers to the distribution of bushing assemblies manufactured at a centralized location for regional mass production factories / plants located closer to the intended point of sale. The relatively small size of bushing assemblies allows large volumes of such bushing assemblies to be shipped effectively at relatively low costs. The high costs associated with extensive cable shipping can be greatly reduced. At regional offices, fiber optic cable connectorized assemblies can be effective and mass-produced in a factory by splicing gland assemblies to cables as described in this document. The high level of precision provided in the ferrules, fiber optics, splicing techniques and manufacturing processes used in the downtown area effectively compensates for the losses associated with the addition of splices to the fiber optic connector assembly means of production. Once again, the large volumes of bushing assemblies manufactured at centralized locations provide the rationale for making the capital investments necessary to provide the level of equipment quality, automation, and precision manufacturing for this system. feasible manufacturing and distribution.

Aspects of the present disclosure allow bushing assemblies to be manufactured in large volumes at manufacturing sites, where the process is most cost effective. The bushings assemblies, which are small in size, can be efficiently shipped in bulk to factory / assembly locations closest to customer facilities, where bushings assemblies can be spliced ​​to fiber optic cables and assembly connecting d finitive can take place. In this way, shipping of the cable itself (which tends to be larger in size and weight) can be minimized. In addition, the final assembly can be done closer to the customer's facilities, thus reducing delivery times. Global supply chains can also be improved.

Aspects of the present disclosure allow bushing assemblies to be manufactured in large volumes at manufacturing sites, where the process is most cost effective. The bushing assemblies, which are small in size, can be efficiently shipped in bulk to factory / mounting locations closer to customer facilities, where bushing assemblies can be spliced ​​to fiber optic cables and mounting definitive connector can take place. In this way, the shipping of the cable itself (which tends to be larger in size and weight) can be minimized. In addition, the final assembly can be done closer to the customer's facilities, thus reducing delivery times. Global supply chains can also be improved.

While various specific dimensions are provided above, it will be appreciated that the dimensions are applicable to some embodiments and that other embodiments within the scope of the present disclosure may use dimensions other than those specifically stated. Similarly, while various manufacturing tolerances are provided above, it will be appreciated that manufacturing tolerances are applicable to some embodiments and that other embodiments within the scope of the present disclosure may utilize manufacturing tolerances other than those specifically intended. The above specification, examples and data provide a description of the inventive aspects of the disclosure. Many embodiments of the disclosure can be made without departing from the spirit and scope of the inventive aspects of disclosure.