Embeddable fiber optic connector and associated method

A composite structure, comprising:

• a plurality of layers defining a surface;
• at least one optical fiber embedded within the layers and operable to transmit a signal therethrough;
• and
• at least one fiber optic connector, each connector comprising:
• a sheath embedded within the plurality of layers and having opposed first and second ends, the first end of the sheath being flush with the surface of the composite structure;
• and
• an internal connector ferrule mounted upon the at least one optical fiber, the internal connector ferrule having a first end snugly disposed proximate the second end of the sheath.

An assembly of fiber optic components for incorporation into a laminated composite structure, the assembly of fiber optic components comprising:

• a sheath with an inside diameter and an outside diameter, the outside diameter being less than 0.1 inches;
• an alignment sleeve comprising a first and second ends and configured to fit within the sheath;
• and
• a pair of connector ferrules capable of being mounted on respective optical fibers, the pair of connector ferrules comprising an external connector ferrule and an internal connector ferrule, the external connector ferrule configured to snugly fit within the first end of the alignment sleeve, the internal connector ferrule configured to snugly fit within the second end of the alignment sleeve such that the optical fibers upon which the pair of connecting ferrules are mounted are operably aligned.

A method of embedding a fiber optic connector, comprising the steps of:

• layering a plurality of plies to form a composite structure;
• positioning the connector proximate an edge of the composite structure during layering of the plies such that a portion of the connector sheath spans a cut line of the composite structure;
• curing the composite structure to consolidate the plies;
• cutting the composite structure along the cut line and through the connector sheath to define a first end of the sheath that is flush with a surface of the composite structure;
• and
• inserting an external connector ferrule into the first end of the sheath so as to establish optical communication between an optical fiber upon which the external connector ferrule is mounted and an optical fiber disposed within the composite structure.