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WO-2026096251-A2 - FERRULES AND FERRULE ASSEMBLIES FOR FIBER OPTIC CONNECTORS HAVING SELF-ALIGNMENT FEATURES

WO2026096251A2WO 2026096251 A2WO2026096251 A2WO 2026096251A2WO-2026096251-A2

Abstract

Ferrules and ferrule assemblies for fiber optic connectors are disclosed that having self-alignment features that improve mating when misaligned. The ferrules may comprise one or more lead-in portions having geometry such as a front end with a ball-shaped portion for improving self-alignment and inhibit excess force of binding during optical mating. The ferrules or ferrule assemblies may use fiber-based or lens-based optical interfaces along with other features as desired. Fiber optic connectors may have other self-aligning features that may be used with the ferrules or ferrule assemblies disclosed herein or with conventional ferrules as desired. One or more ferrules or ferrule assemblies may be disposed within an optical housing of the fiber optic connector such as forming a duplex connector.

Inventors

  • ANDERSON, TIMOTHY WINSTON

Assignees

  • CORNING RESEARCH & DEVELOPMENT CORPORATION

Dates

Publication Date
20260507
Application Date
20251022
Priority Date
20241031

Claims (20)

  1. We claim:
  2. 1. A fiber optic connector (100) comprising:
  3. a ferrule (50) comprising a fiber bore (52) extending from a rear end (51) into the ferrule (50) and an optical interface (58) disposed at a front end (53) of the ferrule (50), wherein the ferrule (50) comprises a lead-in portion (55) at the front end (53) comprising a ball-shaped portion (57) for inhibiting the binding of the ferrule (50) during insertion into a complementary device if laterally misaligned; and
  4. an optical housing (80) comprising a passageway (82) extending from a front end (81) to a rear end (83), wherein the ferrule (50) is configured to be disposed within the optical housing (80) when assembled.
  5. 2. The fiber optic connector of claim 1, wherein the lead-in portion (55) comprises a lead-in diameter (55D) that is smaller than a rearward nominal diameter (52D) of the ferrule (50).
  6. 3. The fiber optic connector of claims 1 or 2, the ferrule (50) further comprising a second lead-in portion (56) disposed rearward of the lead-in portion (55 ).
  7. 4. The fiber optic connector of claim 3, wherein the second lead-in portion (56) comprises angled surface.
  8. 5. The fiber optic connector of claim 2, wherein the rearward nominal diameter (52D) of the ferrule (50) is 1.25 millimeters.
  9. 6. The fiber optic connector of any one of claims 1-5, wherein the ferrule (50) is a portion of a ferrule assembly (40) that comprises a planar surface (68) at a medial portion of the ferrule assembly (40).
  10. 7. The fiber optic connector of any one of claims 1-6, wherein the optical housing (80) comprises an optical housing passageway (85) configured for receiving a portion of the ferrule (50) when assembled, wherein the optical housing passageway (85) has a passageway diameter (85D) that is at least 1.25 times larger than the portion of the ferrule (50) passing through the optical housing passageway (85).
  11. 8. The fiber optic connector of any one of claims 1-7, further comprising a second ferrule (50) comprising a second fiber bore (52) extending from a respective rear end (51) into the second ferrule (50), wherein the second ferrule (50) is configured to be disposed within the optical housing (80) when assembled.
  12. 9. The fiber optic connector of any one of claims 1-8, further comprising a connector body (150) having a longitudinal open slot (150S) and the connector body (150) is configured for receiving a portion of the optical housing (80).
  13. 10. The fiber optic connector of claim 9, the connector body (150) further comprising one or more latching features (159) extending inward toward the longitudinal open slot (150S) and configured for engaging a protrusion (149) disposed on the optical housing (80).
  14. 11. The fiber optic connector of any one of claims 1-10, further comprising a spring (67) for biasing the ferrule (50) to a forward position when the fiber optic connector (100) is assembled.
  15. 12. The fiber optic connector of claim 11, further comprising a spring push (76) configured as a backstop for the spring (67).
  16. 13. The fiber optic connector of any one of claims 1-12, further comprising a connector position assurance (CPA) that cooperates with a latching trigger (152) and is configured for inhibiting the latching trigger (152) from being depressed.
  17. 14. The fiber optic connector of any one of claims 1-13, wherein the ferrule (50) is a portion of a ferrule assembly (60) that further comprises a ferrule holder (40).
  18. 15. The fiber optic connector of any one of claims 1-14, wherein the fiber optic connector (100) is a portion of a cable assembly (120). 16. A fiber optic connector (100) comprising:
  19. a ferrule (50) comprising a fiber bore (52) extending from a rear end (51) into the ferrule (50), and an optical interface (58) disposed at a front end (53) of the ferrule (50), wherein the ferrule (50) comprises a lead-in portion (55) at the front end (53) comprising a ball-shaped portion (57) and the lead-in portion (55) comprises a lead-in diameter (55D) that is smaller than a rearward nominal diameter (52D) of the ferrule (50) for inhibiting the binding of the ferrule (50) during insertion into a complementary device if laterally misaligned; and
  20. an optical housing (80) comprising a passageway (82) extending from a front end (81) to a rear end (83), wherein the ferrule (50) is configured to be disposed within the optical housing (80) when assembled.

Description

FERRULES AND FERRULE ASSEMBLIES FOR FIBER OPTIC CONNECTORS HAVING SELF-ALIGNMENT FEATURES RELATED APPLICATIONS [0001] This application claims the benefit of priority of U. S. Provisional Application Serial No. 63/714,260 filed on October 31, 2024, the content of which is relied upon and incorporated herein by reference in its entirety. FIELD [0002] The disclosure is directed to ferrules and ferrule assemblies for use in fiber optic connectors. The ferrules and ferrule assemblies comprise features at the front end of the ferrule that accommodate lateral misalignment of the ferrule when mating with a suitable device. The ferrule and ferrule assemblies may be used as a portion of fiber optic connectors for mating with another connector or device that receives a portion of the ferrule or ferrule assembly during mating. BACKGROUND [0003] Optical fiber is increasingly being used for a variety of applications, including but not limited to broadband voice, video, and data transmission in a variety of new and expanding applications. As bandwidth demands increase optical fiber is migrating deeper into new and emerging applications for communication networks and systems having requirements that are different from the networks and systems of conventional operator networks. One such new application is for the use of optical fiber for in-vehicle optical networks and the like. As optical fiber extends deeper into these communication networks there exist a need for quickly and easily making optical connections while meeting the requirements and demands for these new and emerging applications. [0004] Fiber optic connectors were developed for making one or more plug and play optical connections using a suitable fiber optic connector for the given application. Fiber optic connectors provide a node for mating and unmating in the optical network and provide the flexibility of locating the connection points in convenient locations for efficient network assembly, access, design and/or deployment. Conventional fiber optic connectors used for telecommunications, are used indoors or inside enclosures for inhibiting moisture, dust, dirt or debris or the like from reaching the mating interface of the fiber optic connector. Hardened fiber optic connectors were developed for outdoor applications that for inhibiting moisture, dust, dirt or debris or the like from reaching the mating interface of the fiber optic connector. However, these hardened fiber optic connectors developed for outdoor applications are relatively large, bulky and/or expensive. [0005] As new applications emerge for the deployment of optical networks the requirements for these new applications may be different and/or have other considerations for the given application. One such emerging application is the use of optical systems on vehicles that present a new environment with specific challenges for successful deployment in potential harsh environments while requiring a relatively compact footprint in a robust and reliable package while enabling reliable mating and unmating of connectors, inspection and serviceability, ease of manufacture and the like. Consequently, there exists an unresolved need for robust fiber optic connectors for reliable mating for preserving optical performance and inhibiting damage to the fiber optic connectors or device being optically connected. SUMMARY [0006] The disclosure is directed to ferrules and ferrule assemblies having selfaligning feature for use with fiber optic connectors (hereinafter “connector(s)”) for optical mating with a complimentary device. The connectors may be configured for supporting one or more ferrules or ferrule assemblies that may be disposed within a housing of the connector when assembled. Additionally, the ferrule or ferrule assemblies may be configured for physical contact or free-space transmission as desired. Further, the ferrule or ferrule assembly may use a lens for optical transmission as desired or not. The connectors that use the ferrules and ferrules assemblies disclosed herein may have any suitable configuration desired. [0007] One embodiment is directed to a ferrule comprising a fiber bore extending from a rear end into a body of the ferrule along with a front end of the ferrule comprising a lead-in portion having a ball-shaped portion for inhibiting the binding of the ferrule during insertion into a complementary device if the ferrule is laterally misaligned. [0008] The disclosure is also directed to a ferrule assembly comprising a fiber bore extending from a rear end into the ferrule assembly and an optical interface disposed at a front end of the ferrule assembly. The ferrule assembly comprises a lead-in portion at the front end comprising a ball-shaped portion for inhibiting the binding of the ferrule assembly during insertion into a complementary device if laterally misaligned. [0009] As used herein, “ball-shaped portion” means a generally ball shape that may be truncated in one or more plan