Methods of making fiber optic connector sub-assemblies

A method of making a fiber optic connector sub-assembly that includes a ferrule having a front end, a rear end, and a ferrule bore extending between the front and rear ends along a longitudinal axis, wherein the ferrule bore includes a first section extending inwardly from the rear end of the ferrule and having a first width, a second section extending inwardly from the front end of the ferrule and having a second width that is less than the first width, and a transition section located between the first section and the second section, the method comprising:

• (a) initially disposing a bonding agent in at least the transition section of the ferrule bore without there being any optical fiber present in the ferrule bore;
• (b) heating at least a portion of the ferrule above a melting temperature of the bonding agent initially disposed in the ferrule bore so that some of the bonding agent melts;
• and
• (c) solidifying the bonding agent that has melted in step (b) to form the fiber optic connector sub-assembly without there being any optical fiber present in the ferrule bore;
• wherein:
• the bonding agent has first and second ends along the longitudinal axis that have been melted and solidified following steps (b) and (c);
• and
• a portion of the bonding agent initially disposed in the ferrule bore in step (a) remains below the melting temperature of the bonding agent during steps (b) and (c) so as to not melt and solidify during steps (b) and (c).

A method of making a fiber optic connector sub-assembly that includes a ferrule having a front end, a rear end, a ferrule bore extending between the front and rear ends along a longitudinal axis, the method comprising:

• (a) initially disposing a bonding agent in the ferrule bore of the ferrule, wherein the bonding agent comprises a powdered material;
• (b) heating at least a portion of the ferrule above a melting temperature of the bonding agent initially disposed in the ferrule bore so that some of the bonding agent melts;
• and
• (c) solidifying the bonding agent that has melted in step (b) to form the fiber optic connector sub-assembly;
• wherein:
• the bonding agent has first and second ends along the longitudinal axis that have been melted and solidified following steps (b) and (c);
• and
• a portion of the bonding agent initially disposed in the ferrule bore in step (a) remains below the melting temperature of the bonding agent during steps (b) and (c) so as to not melt and solidify during steps (b) and (c);
• and further wherein:
• the bonding agent comprises a partially cross-linkable polymer resin;
• the partially cross-linkable polymer resin has a melting point between about 250° C. and about 350° C.;
• and
• the bonding agent that is melted in step (b) is kept below 350° C.