Multi-fiber ferrule-less duplex fiber optic connectors with multi-fiber alignment devices

Abstract

Aspects and techniques of the present disclosure relate to an alignment device that includes a groove-type alignment structure with a support region for receiving an optical fiber inserted along a fiber insertion axis. The optical fiber has a first side and a second, opposite side. The groove-type alignment structure engages the first side of the optical fiber. The alignment device includes a stabilization structure that engages the first side of the optical fiber and a first angled transition surface that engages the second, opposite side of the optical fiber. The present disclosure also relates to an alignment system that includes a first housing piece; a second housing piece adapted to mate with the first housing piece; and a flat structure positioned between the first and second housing pieces.

What is claimed is: 
     
         1 . An optical fiber alignment device having a front end, an opposite rear end, and a mid-plane located between the front and rear ends, the optical fiber alignment device comprising:
 first and second housing pieces adapted to mate together;   the first housing piece including first and second projections with angled transition surfaces respectively positioned between the front and rear ends of the fiber alignment device, the first and second projections respectively having first and second deflection structures;   the second housing piece including first and second stabilization structures respectively positioned adjacent the front and rear ends of the fiber alignment device, the second housing piece defining a groove-type alignment structure, the first and second stabilization structures being elevated above the groove-type alignment structure;   wherein the first projection is positioned between the mid-plane of the optical fiber alignment device and the first stabilization structure, and the second projection is positioned between the mid-plane of the optical fiber alignment device and the second stabilization structure;   first and second optical fibers being respectively inserted through the front and rear ends of the optical fiber alignment device along a fiber insertion axis, ends of the first and second optical fibers being coupled together near the mid-plane of the optical fiber alignment device;   when the first and second optical fibers are inserted, the first and second optical fibers engage the angled transition surfaces such that the first and second optical fibers are flexed downward, the first and second deflection structures make contact with a first side of the first and second optical fibers, respectively, to create stress on the first and second optical fibers while the first and second stabilization structures respectively support the first and second optical fibers, the first and second optical fibers being configured to engage a contact alignment surface of the groove-type alignment structure and to lay within the groove-type alignment structure;   wherein the groove-type alignment structure engages a second side of the first and second optical fibers, and wherein the first and second stabilization structures also engage the second side of the first and second optical fibers, respectively; and   wherein flexure of the first and second optical fibers by the first and second deflection structures and the first and second stabilization structures causes end portions of the first and second optical fibers to lay flat in the groove-type alignment structure under spring load provided by the flexed first and second optical fibers.   
     
     
         2 . The alignment device of  claim 1 , wherein the first and second angled transition surfaces have a taper configuration for guiding the first and second optical fibers into the groove-type alignment structure. 
     
     
         3 . The alignment device of  claim 1 , wherein the first and second angled transition surfaces each have an oblique angle relative to the fiber insertion axis. 
     
     
         4 . The alignment device of  claim 1 , wherein spacing between a respective endface of the first and second angled transition surfaces and respective contact locations of the first and second stabilization structures is overlapping. 
     
     
         5 . The alignment device of  claim 1 , wherein spacing between a respective endface of the first and second angled transition surfaces and respective contact locations of the first and second stabilization structures is less than a diameter of the first and second optical fibers, respectively. 
     
     
         6 . The alignment device of  claim 1 , wherein the first and second optical fibers create a S-curve within the optical fiber alignment device. 
     
     
         7 . A fiber alignment device for receiving an optical fiber of a ferrule-less fiber optic connector, the optical fiber including a first side and an opposite second side, the fiber alignment device including:
 a first piece that defines a fiber deflection structure;   a second piece including a groove-type fiber alignment structure and a fiber stabilization structure that each face in an opposing direction as compared to the fiber deflection structure;   a fiber path for receiving the optical fiber, the fiber path being defined between the first and second pieces, wherein the fiber path includes a first fiber contact location provided by the groove-type fiber alignment structure, a second fiber contact location provided by the fiber deflection structure, and a third fiber contact location provided by the fiber stabilization structure, the first fiber contact location being spaced from the third fiber contact location in an orientation along the fiber path, and the second fiber contact location being positioned between the first and third fiber contact locations in the orientation along the fiber path; and   wherein when the optical fiber has been fully inserted along the fiber path: a) the first side of the optical fiber contacts the second fiber contact location causing the optical fiber to be deflected such that the second side of the optical fiber comes into contact with the first fiber contact location and the third fiber contact location; and b) the optical fiber is flexed between the first and third fiber contact locations by engagement with the second fiber contact location, wherein the inherent elasticity of the flexed optical fiber causes an end portion of the optical fiber to be biased within the groove-type fiber alignment structure at the first fiber contact location.   
     
     
         8 . The fiber alignment device of  claim 7 , wherein not one of the first, second and third fiber contact locations is provided as part of the fiber optic connector. 
     
     
         9 . The fiber alignment device of  claim 7 , wherein the first, second and third fiber contact locations are fixed in position relative to one another regardless of a position of the fiber optic connector. 
     
     
         10 . The fiber alignment device of  claim 7 , wherein the third fiber contact location is elevated relative to the first fiber contact location in a direction toward the first piece. 
     
     
         11 . The fiber alignment device of  claim 7 , wherein when the optical fiber is inserted into the fiber path, the optical fiber does not engage the third fiber contact location until after the optical fiber has been deflected via contact with the second fiber contact location. 
     
     
         12 . The fiber alignment device of  claim 7 , wherein the second piece is formed by an insert molding process in which a single insert is used to define the groove-type fiber alignment structure, the fiber stabilization structure, and the fiber deflection structure for engaging the first piece to ensure precise relative positioning between the first and second pieces. 
     
     
         13 . The fiber alignment device of  claim 7 , wherein the end portion of the optical fiber is at an angle with respect to an axis of the groove-type fiber alignment structure, the angle being less than 1 degree. 
     
     
         14 . The fiber alignment device of  claim 7 , wherein the end portion of the optical fiber is parallel to an axis of the groove-type fiber alignment structure in the fiber alignment device.