Methods for securing an optical fiber to a ferrule and optical connectors formed by such methods

Abstract

A method of securing an optical fiber to a ferrule includes disposing an adhesive composition in a fiber-receiving passage of the ferrule to form a ferrule adhesion system. The adhesive composition in the ferrule adhesion system comprises a polymeric material in a solid form. The method also involves assembling an optical connector with the ferrule adhesion system, heating the ferrule in the optical connector to melt the adhesive composition, and inserting the optical fiber into the fiber-receiving passage of the ferrule and into contact with the adhesive composition that has been melted. The adhesive composition bonds the optical fiber to an inner surface of the ferrule upon cooling and solidifying.

What is claimed is: 
     
         1 . A method of securing an optical fiber to a ferrule, comprising:
 disposing an adhesive composition in a fiber-receiving passage of the ferrule to form a ferrule adhesion system, wherein the, adhesive composition in the ferrule adhesion system comprises a polymeric material in a solid form;   assembling an optical connector with the ferrule adhesion system, wherein the optical connector includes a connector housing in which the ferrule is at least partially disposed;   heating the ferrule in the optical connector to melt the adhesive composition; and   inserting the optical fiber into the fiber-receiving passage of the ferrule and into contact with the adhesive composition that has been melted, wherein the adhesive composition bonds the optical fiber to an inner surface of the ferrule upon cooling and solidifying.   
     
     
         2 . The method of  claim 1 , wherein the ferrule is biased relative to the connector housing when the optical connector is assembled. 
     
     
         3 . The method of  claim 1 , wherein heating the ferrule comprises heating the adhesive composition to a temperature of at least about 300° C. 
     
     
         4 . The method of claim I, wherein heating the ferrule comprises heating the adhesive composition to a temperature of at least about 325° C. 
     
     
         5 . The method of  claim 1 , wherein:
 the polymeric material of the adhesive composition comprises a partially cross-linkable resin prior to the heating step; and   the polymeric material of the adhesive composition comprises a partially cross-linked resin following the cooling step.   
     
     
         6 . The method of  claim 1 , wherein the polymeric material of the adhesive composition comprises poly(phenylene sulfide). 
     
     
         7 . The method of  claim 6 , wherein the adhesive composition comprises the poly(phenylene sulfide) in an amount greater than or equal to about 30% by weight of the adhesive composition. 
     
     
         8 . The method of  claim 7 , wherein the adhesive composition comprises the poly(phenylene sulfide) in an amount greater than or equal to about 50% by weight of the adhesive composition. 
     
     
         9 . The method of  claim 8 , wherein the adhesive composition further comprises a coupling agent that is at least one of the following: an alkoxysilane, an oxime silane, an acetoxy silane, a zirconate, a titanate, a silane with an epoxy ring on one end and trimethoxy functional group at the other end, or combinations thereof. 
     
     
         10 . The method of  claim 9 , wherein the adhesive composition comprises the coupling agent in an amount between about 0.5% and about 20% by weight of the adhesive composition. 
     
     
         11 . The method of  claim 1 , wherein the polymeric material of the adhesive composition comprises poly(phenylene sulfide), and wherein the adhesive composition further comprises a coupling agent that chemically bonds the poly(phenylene sulfide) to an inorganic surface of at least one of the optical fiber and the ferrule following the cooling step. 
     
     
         12 . The method of  claim 11 , wherein the coupling agent that comprises at least one of the following: an alkoxysilane, an oxime silane, an acetoxy silane, a zirconate, a titanate, a silane with an epoxy ring on one end and trimethoxy functional group at the other end, or combinations thereof. 
     
     
         13 . The method of  claim 1 , wherein disposing the adhesive composition in the fiber-receiving passage further comprises:
 forming the adhesive composition in a powder form; and   packing the powder form of the adhesive composition in the fiber-receiving passage.   
     
     
         14 . The method of  claim 1 , wherein disposing the adhesive composition in the fiber-receiving passage further comprises:
 forming the adhesive composition by extruding or injecting molding the adhesive composition a solid preform; and   disposing the lid preform in the fiber-receiving passage of the ferrule.   
     
     
         15 . A method of securing an optical fiber to a ferrule, comprising:
 disposing an adhesive composition in a fiber-receiving passage of the ferrule to form a ferrule adhesion system, wherein the adhesive composition comprises a polymeric material in a solid form;   storing the adhesive composition, in the solid form, in the fiber-receiving passage of the ferrule for at least 8 hours;   heating the ferrule to melt the adhesive composition after the storing step; and   inserting the optical fiber into the fiber-receiving passage of the ferrule and into contact with the adhesive composition that has been melted, wherein the adhesive composition bonds the optical fiber to an inner surface of the ferrule upon cooling and solidifying.   
     
     
         16 . The method of  claim 15 , wherein the adhesive composition is stored, in the solid form, in the fiber-receiving passage of the ferrule for at least 1 day. 
     
     
         17 . The method of  claim 15 , wherein heating the ferrule comprises heating the adhesive composition to a temp nature of at least about 300° C. 
     
     
         18 . The method of  claim 15 , wherein the polymeric material of the adhesive composition comprises poly(phenylene sulfide). 
     
     
         19 . The method of  claim 18 , wherein the adhesive composition comprises the poly(phenylene sulfide) in an amount greater than or equal to about 50% by weight of the adhesive composition. 
     
     
         20 . The method of  claim 19 , wherein the adhesive composition further comprises a coupling agent that is at least one of the following: an alkoxysilane, an oxime silane, an acetoxy silane, a zirconate, a titanate, a silane with an epoxy ring on one end and trimethoxy functional group at the other end, or combinations thereof. 
     
     
         21 . The method of  claim 20 , wherein the adhesive composition comprises the coupling agent in an amount between about 0.5% and about 20% by weight of the adhesive composition.