Fiber optic connector having an optical fiber that is axially moveable within a ferrule

Abstract

A fiber optic connector ( 20 ) including a ferrule ( 42 ) having a front end ( 48 ) and a rear end ( 50 ). The ferrule ( 42 ) defines an axial bore ( 46 ) that extends through the ferrule ( 42 ) between the front end ( 48 ) and the rear end ( 50 ). The ferrule ( 42 ) includes a ferrule axis ( 64 ) that extends along the axial bore ( 46 ). The fiber optic connector ( 20 ) includes an optical fiber ( 62 ) positioned within the axial bore ( 46 ) that is movable relative to the ferrule ( 42 ) within the axial bore ( 46 ) along the ferrule axis ( 64 ). The optical fiber ( 62 ) has fiber end face ( 63 ) that has been energy treated to round the fiber end face ( 63 ). A fiber alignment structure ( 66 ) can be attached at a front ferrule end face ( 54 ) of the ferrule ( 42 ). A camera can be used to position a fiber end face ( 63 ) of the optical fiber ( 62 ) relative to the front ferrule end face ( 54 ) of the ferrule ( 42 ).

1 . (canceled) 
     
     
         2 . A method for assembling a fiber optic connector, the fiber optic connector including a ferrule having a front end and a rear end, the ferrule defining an axial bore that extends through the ferrule between the front end and the rear end, the ferrule including a ferrule axis that extends along the axial bore, the fiber optic connector including an optical fiber positioned within the axial bore that is movable relative to the ferrule within the axial bore along the ferrule axis, the fiber optic connector also including a connector body in which the ferrule is mounted, the method comprising:
 inserting the optical fiber in the axial bore; and   aligning a fiber end face of the optical fiber within the axial bore at a front ferrule end face including radially biasing the optical fiber.   
     
     
         3 . The method of  claim 2 , wherein radially biasing the optical fiber includes sliding the optical fiber through a fiber alignment structure disposed at the front ferrule end face. 
     
     
         4 . The method of  claim 3 , wherein the fiber alignment structure is fully disposed within an outer diameter of the ferrule. 
     
     
         5 . The method of  claim 4 , wherein the fiber alignment structure includes a plurality of deflectable beams extending towards the ferrule axis from an inner surface of the axial bore. 
     
     
         6 . The method of  claim 3 , wherein the fiber alignment structure includes a plurality of deflectable beams extending towards the ferrule axis from an inner surface of the axial bore. 
     
     
         7 . The method of  claim 2 , further comprising axially fixing the optical fiber relative to the connector body. 
     
     
         8 . The method of  claim 2 , further comprising energy treating the fiber end face before or after the optical fiber has been inserted within the ferrule. 
     
     
         9 . The method of  claim 2 , further comprising using a camera to determine a positional relationship between the fiber end face of the optical fiber and the front ferrule end face of the ferrule. 
     
     
         10 . The method of  claim 9 , further comprising repositioning the fiber end face relative to the ferrule based on a feed-back loop from the camera. 
     
     
         11 . The method of  claim 10 , wherein repositioning the fiber end face includes sliding the optical fiber within the axial bore. 
     
     
         12 . An optical ferrule assembly comprising:
 a ferrule having a front end and a rear end, the ferrule defining an axial bore that extends through the ferrule between the front end and the rear end, the ferrule including a ferrule axis that extends along the axial bore;   an optical fiber positioned within the axial bore of the ferrule to extend rearwardly from the rear end of the ferrule, the optical fiber being movable relative to the ferrule within the axial bore along the ferrule axis, the optical fiber having a fiber end face disposed at the front end of the ferrule; and   a fiber alignment structure disposed at the front end of the ferrule, the fiber alignment structure defining a fiber passage through which the optical fiber extends so that the fiber end face is biased into an aligned position relative to the ferrule.   
     
     
         13 . The optical ferrule assembly of  claim 12 , wherein the fiber alignment structure is a separate insert attached to the ferrule. 
     
     
         14 . The optical ferrule assembly of  claim 12 , wherein the fiber alignment structure includes one or more alignment projections that facilitate aligning the optical fiber. 
     
     
         15 . The optical ferrule assembly of  claim 14 , wherein the alignment projections extend in a radial direction relative to the optical fiber. 
     
     
         16 . The optical ferrule assembly of  claim 15 , wherein the fiber alignment structure has an elastic construction that allows the alignment projections to elastically move radially when an optical fiber is inserted through the fiber alignment structure. 
     
     
         17 . The optical ferrule assembly of  claim 14 , wherein the alignment projections are uniformly distributed circumferentially about the fiber passage of the fiber alignment structure 
     
     
         18 . The optical ferrule assembly of  claim 14 , wherein the alignment projections have end tips that define the circumferential boundary of the fiber passage and are configured to engage the optical fiber at the fiber passage. 
     
     
         19 . The optical ferrule assembly of  claim 14 , wherein the alignment projections flexes radially outwardly to accommodate the optical fiber and to self-center the optical fiber along the fiber passage when optical fiber is inserted through the fiber passage of the fiber alignment device. 
     
     
         20 . The optical ferrule assembly of  claim 19 , wherein the alignment projections elastically clamp and apply self-centering spring loads to the optical fiber to center the optical fiber along the fiber passage. 
     
     
         21 . The optical ferrule assembly of  claim 12 , wherein the fiber passage aligns with the ferrule axis.