Optical fiber assemblies and methods of forming the same
AssigneeCorning Research & Development Corporation
InventorsJames Daniel Blackburn, Xiaole Cheng, John Patrick Lammers, Darrin Max Miller, Stephan Toepper
Life of this patent
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Abstract
Methods of forming an optical fiber assembly involve placing an adhesive in a ferrule assembly, heating the ferrule assembly through thermal induction, inserting an optical fiber into the ferrule bore during or after the heating step, and securing the optical fiber to the ferrule assembly using the adhesive. The thermal induction causes the adhesive to efficiently take or maintain a melted form to allow the optical fiber insertion.
Claims21
A method of forming an optical fiber assembly, wherein the optical fiber assembly includes a ferrule and a ferrule holder, the ferrule having a front portion defining a front end, a rear portion defining a rear end, and a ferrule bore extending between the front end and the rear end, and wherein the ferrule holder receives the rear portion of the ferrule and together with the ferrule defines a ferrule assembly, the ferrule holder comprising metal and having a ferrule holder passage that communicates with the ferrule bore, the method comprising the steps of:
- placing a thermoplastic adhesive in the ferrule assembly, wherein the thermoplastic adhesive is placed in ferrule holder passage, the ferrule bore, or both the ferrule holder passage and the ferrule bore;
- heating the ferrule assembly through thermal induction, wherein the heating causes the thermoplastic adhesive to take or maintain a melted form, and wherein the heating comprises:
- positioning the ferrule assembly relative to an induction coil and a metal sleeve that is separate from the induction coil, wherein the positioning includes receiving the front portion of the ferrule within the metal sleeve, and wherein the positioning results in the metal sleeve being positioned between the ferrule and the induction coil;
- and
- causing electrical current to flow through the induction coil, wherein the electrical current generates a magnetic field that induces heat generation in the ferrule holder to cause the thermoplastic adhesive to take or maintain a melted form, and wherein the metal sleeve remains positioned over the front portion of the ferrule when causing the electrical current to flow through the induction coil so that the electrical current induces heat generation in the metal sleeve;
- inserting an optical fiber into the ferrule bore during or after the heating step, wherein the temperature of the ferrule maintains the thermoplastic adhesive in the melted form during the inserting;
- and
- securing the optical fiber to the ferrule assembly using the thermoplastic adhesive, wherein the thermoplastic adhesive solidifies during the securing.
An optical fiber assembly formed by:
- placing an adhesive in a ferrule assembly that includes a ferrule and a ferrule holder, wherein:
- the ferrule has a front portion defining a front end, a rear portion defining a rear end, and a ferrule bore extending between the front end and the rear end,
- the ferrule holder is received over the rear portion of the ferrule, comprises metal, and has a ferrule holder passage that communicates with the ferrule bore, and
- the adhesive is placed in ferrule holder passage, the ferrule bore, or both the ferrule holder passage and the ferrule bore;
- heating the ferrule assembly through thermal induction, wherein the heating causes the adhesive to take or maintain a melted form, and wherein the heating comprises:
- positioning the ferrule assembly relative to an induction coil and a metal sleeve that is separate from the induction coil, wherein the positioning includes receiving the front portion of the ferrule within the metal sleeve, and wherein the positioning results in the metal sleeve being positioned between the ferrule and the induction coil;
- and
- causing electrical current to flow through the induction coil, wherein the electrical current generates a magnetic field that induces heat generation in the ferrule holder to cause the adhesive to take or maintain a melted form, and wherein the metal sleeve remains positioned over the front portion of the ferrule when causing the electrical current to flow through the induction coil so that the electrical current induces heat generation in the metal sleeve;
- inserting an optical fiber into the ferrule bore during or after the heating step, wherein the temperature of the ferrule maintains the adhesive in the melted form during the inserting;
- and
- securing the optical fiber to the ferrule assembly using the adhesive, wherein the adhesive solidifies during the securing.
An optical connector, comprising:
- an optical fiber;
- a ferrule terminating the optical fiber, wherein the ferrule has a front portion defining a front end, a rear portion defining a rear end, and a ferrule bore extending between the front end and the rear end;
- a ferrule holder received over the rear portion of the ferrule, wherein the ferrule holder comprises metal and has a ferrule holder passage that communicates with the ferrule bore;
- a connector body in which the ferrule holder is positioned, wherein the connector body comprises a polymer material having a heat deflection temperature at 1.82 MPa according to ASTM D648;
- and
- an adhesive securing the optical fiber to the rear end of the ferrule and at least a portion of the ferrule bore, wherein the adhesive has a melting point above the heat deflection temperature of the connector body.
Dependencies are inferred from the claim text.