Ferrule-less multi-fiber connectors

Abstract

A connection system includes an optical connector assembly; and an optical plug. The connector assembly includes a stack of gel-groove assemblies and a spring assembly mounted within a housing. Each of the gel-groove assemblies includes a first gel block at a first axial end, a second gel block at a second axial end, and a fiber mating region between the first and second gel blocks. The optical plug including sub-modules over-molded over arrays (e.g., ribbons) of the optical fibers. Each sub-module defines notches for receiving latches of the spring assembly when the optical plug is coupled to the first axial end of the optical adapter. Bare optical fibers extend from the plug, pass through the first axial gel block, and enter the fiber mating region when the plug is coupled to the adapter.

1 . (canceled) 
     
     
         2 . An optical plug connector arrangement configured to be inserted into an adapter having v-grooves, the optical plug connector arrangement having a longitudinal axis, the optical plug connector arrangement comprising:
 an optical cable including a plurality of optical fibers;   a plurality of holders held together in a stack, each holder surrounding a respective subset of the optical fibers so that the optical fibers are disposed in parallel rows when the holders are arranged in the stack, each holder extending along a length between opposite first and second ends, the length extending along the longitudinal axis of the optical plug connector arrangement, the holders being disposed at intermediate locations along the optical fibers so that distal ends of the optical fibers extend outwardly beyond the second end of the respective holders; and   a plug housing surrounding at least a portion of the stack of holders, the plug housing defining a plug end face through which the distal ends of the optical fibers extend a sufficient distance to extend along the v-grooves of the adapter.   
     
     
         3 . The optical plug connector arrangement of  claim 2 , wherein the plug housing includes:
 a first housing receiving the stack of holders so that the first housing surrounds at least a portion of each holder, the second end of each holder being disposed external of the first housing; and   a second housing coupled to the first housing to define the plug end face.   
     
     
         4 . The optical plug connector arrangement of  claim 2 , wherein each holder surrounds buffered portions of the optical fibers of the respective subset. 
     
     
         5 . The optical plug connector arrangement of  claim 2 , wherein each holder is overmolded around the optical fibers of the respective subset. 
     
     
         6 . The optical plug connector arrangement of  claim 2 , wherein the subsets of the optical fibers are based on fiber ribbons. 
     
     
         7 . The optical plug connector arrangement of  claim 2 , wherein the holders are held together via a pin extending through aligned apertures defined by the holders. 
     
     
         8 . The optical plug connector arrangement of  claim 2 , wherein the first end of each holder is disposed within the first housing. 
     
     
         9 . The optical plug connector arrangement of  claim 2 , wherein the plug housing includes an extension to which the optical cable is anchored. 
     
     
         10 . The optical plug connector arrangement of  claim 9 , wherein the extension includes a crimp housing over which a crimp sleeve is mounted. 
     
     
         11 . The optical plug connector arrangement of  claim 2 , further comprising a boot coupled to the plug housing. 
     
     
         12 . The optical plug connector arrangement of  claim 2 , wherein the plurality of holders includes six holders. 
     
     
         13 . The optical plug connector arrangement of  claim 2 , wherein the plug housing indicates a polarity of the optical fibers. 
     
     
         14 . The optical plug connector arrangement of  claim 2 , wherein the plug housing has a rectangular transverse cross-sectional profile. 
     
     
         15 . A method of manufacturing an optical plug connector comprising:
 stripping a jacket from an optical cable;   separating optical fibers of the optical cable into groups;   disposing a respective holder around each group of the optical fibers so that distal ends of the optical fibers extend outwardly from the holders;   processing the distal ends of the optical fibers extending outwardly from the holders including stripping the optical fibers resulting in bare optical fibers, cleaning the bare optical fibers, and cutting the optical fibers, thereby resulting in processed ends of the optical fibers;   arranging the holders in a stack; and   assembling a plug connector housing around the stack of holders so the processed ends of the optical fibers extend from the plug connector housing.   
     
     
         16 . The method of  claim 15 , wherein assembling the plug connector housing includes disposing a first housing around at least a portion of the stack of holders and coupling a plug housing to the first housing. 
     
     
         17 . The method of  claim 16 , wherein disposing the first housing around the portion of the stack of holders includes sliding the first housing around first ends of the holders while opposite second ends of the holders remain external of the first housing. 
     
     
         18 . The method of  claim 16 , wherein coupling the plug housing to the first housing includes disposing the plug housing around an exterior of the first housing. 
     
     
         19 . The method of  claim 15 , wherein disposing a respective holder around each group of the optical fibers includes overmolding the holders around the respective groups of the optical fibers. 
     
     
         20 . The method of  claim 15 , wherein separating the optical fibers into groups includes separating ribbons of the optical fibers. 
     
     
         21 . The method of  claim 15 , wherein cutting the optical fibers includes cutting the distal ends of the optical fibers at an angle.