LENSED FIBER OPTIC FERRULE WITH SIMPLIFIED MOLDING

[0001] This application claims priority under 35 U.S.C. § 119 (e) to U.S. provisional application no. 62/930,754 filed on Nov. 5, 2019, and under 35 U.S.C. § 120 to U.S. patent application Ser. No. 17/768,414, filed on Apr. 12, 2022, and to U.S. patent application Ser. No. 18/460,651, filed on Sep. 4, 2023, the contents of which are hereby incorporated by reference in their entirety.

[0002] Many types of single and multi-fiber fiber optic ferrules have integrated lenses and are available in the fiber optic connector industry today. These ferrules are made, at least partially, from an optically clear material. One such lensed ferrule is the PRIZM® MT® ferrule (or, PMT ferrule) provided by the Applicant. The PMT ferrule has lenses on its end-face. The lenses are positioned generally along the same plane that is orthogonal to the optical beam propagating therethrough. Molding the integral lenses and the ferrule requires two or more moving parts of the mold.

[0003] There is a need in the fiber optic connector industry to continuously improve the loss performance of current multi-fiber lensed ferrules. One limiting factor has its roots in the basic manufacturing (molding) process. Current molding processes for lensed ferrules have two or more moving parts that need to move prior to the finished ferrule being ejected from the mold. One of the moving parts of the mold is the mold core that creates the lenses that are adjacent to the end face of the ferrule. By requiring the lens core to move between every injection cycle, there is added uncertainty in controlling the location of the lens core relative to the rest of the mold. Since the ferrule is ejected in a direction perpendicular to the end face, it is advantageous to create a ferrule end face with a refractive lens that does not contain an undesirable undercut relative to the ejection direction.

[0004] Thus, there is a need for a to create a ferrule end face with a refractive lens that does not contain an undesirable undercut relative to the ejection direction. Applicant has developed a new type of a lensed ferrule, where the core that holds the lenses is fixed and does not move at the end of the molding process when the ferrule is ejected. Only the core that creates the guide pin holes or alignment features of the ferrule moves back and the ferrule is released from the mold.

[0005] The present invention is directed to a fiber optic ferrule for receiving a plurality of optical fibers in optical fiber support structures that includes a main body extending between a front end and rear end, the main body having a top surface and a bottom surface, the top surface and the bottom surface having different lengths between the front end and the rear end, a longitudinal axis extending between the front end and the rear end and parallel to the optical fiber support structures, a front face at the front end of the main body, the front face being non-perpendicular to the longitudinal axis, a recessed portion at the front face, a plurality of optical lenses within the recessed portion, wherein the front face has a plurality of points that lie on a plurality of vertical axes extending between the bottom surface and top surface, wherein each of the plurality of points are even with or rearward of the each of the plurality points thereabove.

[0006] In some embodiments, the plurality of optical lenses are in at least one row extending between side surfaces of the fiber optic ferrule.

[0007] In some embodiments, the length of the bottom surface is shorter than the length of the top surface.

[0008] In other embodiments, the fiber optic ferrule is ejected in a direction parallel to the vertical axes after a molding process.

[0009] In some embodiments, each of the plurality of points are even with or forward of the each of the plurality points therebelow.

[0010] In yet another aspect, there is a fiber optic ferrule for receiving a plurality of optical fibers in optical fiber support structures that includes a main body extending between a front end and rear end, the main body having a top surface and a bottom surface, the top surface and the bottom surface having different lengths between the front end and the rear end, a longitudinal axis extending between the front end and the rear end and parallel to the optical fiber support structures, a front face at the front end of the main body, the front face being non-perpendicular to the longitudinal axis, a recessed portion at the front face, a plurality of optical lenses within the recessed portion, wherein the front face has a plurality of points that lie on a plurality of vertical axes extending between the bottom surface and top surface, wherein each of the plurality of points are even with or forward of the each of the plurality points therebelow.

[0011] And in yet another aspect, there is a provided a fiber optic ferrule for receiving a plurality of optical fibers in optical fiber support structures that includes a main body extending between a front end and rear end, the main body having a top surface and a bottom surface, the top surface being longer than the bottom surface, a longitudinal axis extending between the front end and the rear end and parallel to the optical fiber support structures, a front face at the front end of the main body, the front face being non-perpendicular to the longitudinal axis, a recessed portion at the front face, a plurality of optical lenses within the recessed portion, wherein the fiber optic ferrule is moved in a direction orthogonal to the top surface post molding.

[0012] It is to be understood that both the foregoing general description and the following detailed description of the present embodiments of the invention are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention, and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments of the invention and, together with the description, serve to explain the principles and operations of the invention.

[0020] Reference will now be made in detail to the present preferred embodiment(s) of the invention, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.

[0021] Applicant notes that the term “front” or “forward” means that direction where the fiber optic connector and/or the ferrule would meet with another fiber optic connector or device, while the term “rear” or “rearward” is used to mean the direction from which the optical fibers enter into the fiber-optic ferrule or fiber optic connector. Each of the fiber optic ferrules will therefore have a front and rear, and the two fronts or forward portions of the fiber optic ferrules would engage one another. Thus, in FIG. 1, the “front” of the fiber optic ferrule is on the left side of FIG. 1 and “forward” is to the left and out of the page. “Rearward” or “back” is that part of the fiber optic connector that is on the right side of the page and “rearward” and “backward” is toward the right and into the page.

[0022] One embodiment of a fiber optic ferrule 100 according to the present invention is illustrated in FIGS. 1-7. The fiber optic ferrule 100 has a main body 102 extending between a front end 104 and a rear end 106, the main body 102 has a forward portion 108 and a rearward portion 110. The forward portion 108 is separated from the larger rearward portion 110 by a shoulder 112. The fiber optic ferrule 100 may not have the larger rearward portion 110, but whole main body 102 would have the same height and width as the forward portion 108.

[0023] The fiber optic ferrule 100 has a top 114, a bottom 116, and two sides 118, 120. The forward portion 108 has a top surface 130 and a bottom surface 132, the top surface 130 and the bottom surface 132 having lengths L1, L2, respectively. The lengths L1, L2 may be the different or, in another embodiment, they may be same. As illustrated in FIGS. 1 and 3, the lengths L1, L2 are measured between the front end 104 and the shoulder 112. If the fiber optic ferrule 100 were of a uniform height and width as noted above, then the lengths could be measured from the front end 104 to the rear end 106. The two sides 118, 120 each have a side surface 134, 136, respectively (see FIG. 2). It should be noted that the rearward portion 110 also has a top surface 130a, a bottom surface 132a, and side surfaces 134a, 136a, respectively. While the top surface 130 is illustrated as being the longer surface, it is also possible for the bottom surface 132 to be longer, so long as the main body has the appropriate configurations as described herein thus it may only be a semantic change from “top” to “bottom.”

[0024] There is a front face 140 positioned at the front end 104. Preferably the front face 140 has a recessed portion 142. There may also be alignment structures 144, which in one form takes the shape of guide pin holes. The alignment structures 144 may or may not open at the front face 140 within the recessed portion 142. The recessed portion 142 may be completely encircled by the front face 140, or the recessed portion 142 may extend to the top 114 or the bottom 116 or one of the sides 118, 120.

[0025] The main body 102 has an opening 150 that extends from the rear end 106 towards the front end 104 to receive optical fibers within the fiber optic ferrule 100. The main body 102 has optical fiber support structures 152 within the opening 150. The optical fiber support structures 152 could be micro-holes, v-shaped grooves or other configurations that support and align the optical fibers. The fiber optic ferrule 100 has a longitudinal axis A that is parallel to the optical fiber support structures 152 and the optical fibers that are inserted into the fiber optic ferrule. See FIGS. 3 and 4.

[0026] Turning to FIG. 3, the effect of the differing lengths L1, L2 is that the front face 104 makes an angle a other than 90° with the longitudinal axis A. Typically the angle a is about 84° but could be larger or smaller depending on a number of factors, for example, return loss, fiber mode, etc. It should be noted that the fiber optic ferrule 100 is usually mated with another ferrule that has the same configuration but is flipped 180° about the longitudinal axis so that the two front faces 104 are parallel to one another.

[0027] Turning to FIGS. 1-2 and 5-7, the recessed portion 142 has a number of different areas that stretch across at least a portion of the front face 140. As illustrated herein, there are two areas 160,162 with a plurality of integral lenses 164 in rows. See FIGS. 2 and 6 in particular. It is also possible that there be more or fewer rows on integral lenses in the fiber optic ferrule 100. There is also an area 166 above the first area 160 of integral lenses 164. There is another area 168 that is between the two areas 160,162 with the plurality of integral lenses 164. Finally, there is a third area 170 below the second area 162 of integral lenses 164.

[0028] For each row of integral lenses 164, each integral lens, or a portion thereof that is exposed, is at a tilt angle θ to the vertical/Y-axis. The term “integral” as applied to the integral lenses 164 refers to the lenses being molded together with the main body 102, and not being positioned separately onto the front face 140 or the recessed portion 142 thereof. For example and with reference to FIGS. 6 and 7, the top lens is shown at the tilt angle θ relative to the top lens tangent line. Likewise, the bottom lens is at the same tilt angle relative to the bottom lens tangent line. Typically, θ is approximately 22°.

[0029] With reference to FIG. 2, there are a plurality of vertical lines or axes B that can be used with reference to the front face 140. Each of these vertical axis B are perpendicular to the longitudinal axis A. Only four vertical lines or axes B are illustrated in FIG. 2. Indeed, there are theoretically an infinite number of vertical lines or axes B that could be placed on the front face 140 of the fiber optic ferrule 100. The front face 140, including the recessed portion 142, is made up of plurality of points 172 (indeed, also theoretically an infinite number of points). FIGS. 6 and 7 are representations from the left side of the fiber optic ferrule 100 of some of the points 172 on the front face of the fiber optic ferrule along one of the vertical axes B. This view allows for the description of the points 172 relative to the other points along one of the vertical axes B that is not possible to see in a front view image, i.e., FIG. 2.

[0030] The top 114 of the fiber optic ferrule 100 would be at the top of the page (or even beyond) as only a portion of the front face 140 is illustrated in FIGS. 6 and 7. It is the same consideration for the bottom 116, which is below where the figures are labeled. The solid dark line on the very left of the images is the front face 140, that makes the angle a with the top 114 and bottom 116. As can be understood (and with reference to FIGS. 3 and 4) the front face 140 at the top of the fiber optic ferrule 100 is the forward-most (the leftmost point in FIGS. 3 and 4) point on the fiber optic ferrule 100 along the vertical axis B. The next solid line demonstrate the points 172 that make up the recessed portion 142 and includes the areas 160,162 with a plurality of integral lenses 164 and the spacing areas 166, 168 and 170 (and the front face 140 if the figure showed such). For each point 172 along the front face 140 and the recessed portion 142 and along the vertical axis B, the point directly above it is either even with or in front of (to the left in FIGS. 6 and 7) that point. For example a point P1 (a reference point) is illustrated in FIG. 6 as well as a second point P2. It is clear from FIG. 6, that P2 is either directly above or in front of (to the left) of P1. P2 is not behind or to the right of P1, eliminating any undercut on the front face 140 of the fiber optic ferrule 100. Conversely, using P2 as the first (reference) point, then P1 (a point below P2) is either directly below or behind P2. Because of this relationship of the points 172 along the vertical axes, there is no undercut on the front face 140 of the fiber optic ferrule 100. This relationship allows the fiber optic ferrule 100 to be ejected from mold in a vertical direction (perpendicular to the top surface 130) and upward in FIGS. 6 and 7 without removing or moving more of the mold—e.g., that part that forms the front face 140.

[0031] As illustrated in FIG. 7, the integral lenses 164 in area 160 are further to the left than the integral lenses 164 in the lower area 162. Again, this contributes to the elimination of the undercut in a typical fiber optic ferrule where, if the lenses are aligned on a vertical axis, there would be areas of undercut. The integral lenses 164 may be portions of a sphere, although other non-spherical refractive surfaces that are at a similar tilt as the integral lenses 164 could be used in another embodiment.

[0032] It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention. Thus it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.