Fiberoptic connector assembly and method and device for the manufacture thereof

Abstract

A fiberoptic connector assembly which includes an optical fiber that is engaged within a fiberoptic connector. The fiberoptic connector includes a metal core having a malleable external tip. The tip is deformed by physical contact during the manufacturing process, whereby the optical fiber is held within the fiberoptic connector by mechanical frictional engagement with the deformed portion of the tip. The manufacturing device includes a holder for holding the fiberoptic connector with the optical fiber disposed therewithin. A mechanical spring-loaded punch is utilized to make physical contact with the malleable tip of the fiberoptic connector to deform the tip upon physical contact with the punch. Also disclosed is the method that is utilized for manufacturing the fiberoptic connector assembly.

What is claimed is: 
     
       1. A method for assembling a fiberoptic connector and an optical fiber, comprising: constructing a fiberoptic connector such that it includes an optical fiber bore and a mechanically deformable portion disposed proximate said optical fiber bore;   inserting an optical fiber into said bore, such that portions of said optical fiber are disposed adjacent said deformable portion of said fiberoptic connector;   mechanically deforming said deformable portion such that said optical fiber .Iadd.thereby .Iaddend.becomes frictionally engaged within said fiberoptic connector. ...!..Iadd.; and   wherein the deformable portion comprises a metal, and wherein the deformable portion is substantially uniformly swaged around a portion of the optical fiber, thereby frictionally adhering the deformable portion and the portion of optical fiber together.Iaddend..   
     
     
       2. A method for assembling a fiberoptic connector and an optical fiber as described in claim 1 further including the steps of symmetrically deforming said deformable portion, such that said optical fiber is held in a centrally disposed orientation relative to said bore of said fiberoptic connector. 
     
     
       3. A method for assembling a fiberoptic connector and an optical fiber as described in claim 2, further including the steps of crimping a rearwardly projecting portion of said fiberoptic connector about said optical fiber to mechanically engage said optical fiber therewithin. 
     
     
       4. A method for assembling a fiberoptic connector and an optical fiber as described in claim 2 further including the steps of inserting a sleeve member around rearward portions of said fiberoptic connector, such that said sleeve portion also surrounds portions of said optical fiber; and crimping said sleeve member about said rearwardly disposed portions of said fiberoptic connector and about said portions of said optical fiber to mechanically join said optical fiber to said rearward portions of said fiberoptic connector.   
     
     
       5. A fiberoptic connector assembly device for connecting a fiberoptic connector to an optical fiber comprising: a support means, said support means including a fiberoptic connector holding means being engaged thereto;   a connector engagement means, said connector engagement means being engaged to said support means and functioning to effect the connection of said fiberoptic connector to said optical fiber; movement means, said movement means being engaged to said support means and operable to cause said connector engagement means to make physical contact with said fiberoptic connector, whereby said connector engagement means will cause portions of said fiberoptic connector to become deformed upon said physical contact such that said optical fiber will become functionally engaged within said fiberoptic connector; and   wherein said fiberoptic connector holding means is pivotally engaged to portions of said support means.   
     
     
       6. A fiberoptic connector assembly device for effecting the frictional engagement of an optical fiber within a fiberoptic connector, wherein said fiberoptic connector includes a deformable portion that may be mechanically deformed to frictionally engage said optical fiber therewithin, comprising: support means. .;.!..Iadd., wherein said support means includes a base member and first and second opposing side members, said first and second side members being fixedly engaged to said base member;   said support means including two rail members being engaged between said side members in a generally parallel relationship;   connector engagement means support member, said connector engagement means support member being slidably engaged to said rail members and operating to hold said connector engagement means between said rail members; .Iaddend.   fiberoptic connector holding means for holding said fiberoptic connector and an optical fiber disposed therewithin during assembly. .;.!..Iadd., said fiberoptic connector holding means being pivotally engaged to one of said rail members and having a connector holding bore formed therethrough in generally parallel relationship to said rail members, whereby said fiberoptic connector is held for assembly between said rail members;   said fiberoptic connector holding means being disposed in a spaced apart relationship relative to said first side member; an optical fiber slot being formed through portions of said first side member, said optical fiber slot being formed in axial alignment with said connector holding bore, such that an engagement end of said fiberoptic connector will project through said connector holding bore of said fiberoptic connector holding means, and a rearward end of said fiberoptic connector will butt against portions of said first side member proximate said optical fiber slot, and said optical fiber disposed within said fiberoptic connector will project through said slot; .Iaddend.   connector engagement means, said connector engagement means being engaged to portions of said support means;   movement means, said movement means being engaged to portions of said support means and operable to cause said connector engagement means to make physical connect with said deformable portion of said fiberoptic connector, whereby said deformable portion of said fiberoptic connector will become mechanically deformed proximate said optical fiber upon the occurrence of said physical contact, such that said optical fiber will become frictionally engaged within said fiberoptic connector. ...!..Iadd.; and   said movement means being engaged to said second side member, said movement means including a pushing means operable to push said connector engagement means towards said fiberoptic connector holding means.Iaddend.. . .7. A fiberoptic connector assembly device as described in claim 6 wherein said support means includes a base member and first and second opposing side members, said first and second side members being fixedly engaged to said base member;   said support means including two rail members, said rail members being engaged between said side members in a generally parallel relationship;   connector engagement means support member, said connector engagement means support member being slidably engaged to said rail members and operating to hold said connector engagement means between said rail members;   said fiberoptic connector holding means being pivotally engaged to one of said rail members and having a connector holding bore formed therethrough in generally parallel relationship to said rail members, whereby said fiberoptic connector is held for assembly between said rail members;   said fiberoptic connector holding means being disposed in a spaced apart relationship relative to said first side member an optical fiber slot being formed through portions of said first side member, said optical fiber slot being formed in alignment with said connector holding bore, such that an engagement end of said fiberoptic connector will project through said connector holding bore of said fiberoptic connector holding means, and a rearward end of said fiberoptic connector will butt against portions of said first side member proximate said optical fiber slot, and said optical fiber disposed within said fiberoptic connector will project through said slot;   said movement means being engaged to said second side member, said movement means including a pushing means operable to push said connector engagement   
     
     
        means towards said fiberoptic connector holding means..!.8. A fiberoptic connector assembly device as described in claim . .7.!. .Iadd.6 .Iaddend.wherein said connector engagement means includes a spring loaded punch means, said punch means having an impact nose disposed for making contact with said fiberoptic connector to mechanically deform said 
     
     
        deformable portion of said fiberoptic connector. 9. A fiberoptic connector assembly device as described in claim 8 wherein said nose portion of said 
     
     
        punch means includes a connector deformation bore formed therein. 10. A fiberoptic connector assembly device as described in claim 9 wherein said connector deformation bore includes a conical portion, said conical portion being disposed to make contact with said deformable portion of said fiberoptic connector, whereby said deformable portion of said fiberoptic connector will be uniformly deformed about said optical fiber, such that said optical fiber will become frictionally engaged in a 
     
     
        centrally disposed orientation relative to said fiberoptic connector. 11. A fiberoptic connector assembly, comprising: a fiberoptic connector, said fiberoptic connector including an axial optical fiber bore being formed therethrough;   said fiberoptic connector having at least one mechanically deformable portion disposed proximate said optical fiber bore;   an optical fiber being disposed within said optical fiber bore;   said mechanically deformable portion being deformed adjacent said optical fiber, such that segments of said deformable portion are frictionally engaged to said optical fiber to hold said optical fiber within said fiberoptic connector. ...!..Iadd.;   wherein the deformable portion comprises a metal, and wherein the deformable portion is substantially uniformly swaged around a portion of the optical fiber, thereby frictionally adhering the deformable portion   
     
     
        and the portion of optical fiber together.Iaddend.. 12. A fiberoptic connector assembly as described in claim 11 wherein said deformable portion includes a metallic member forming portions of said optical fiber 
     
     
        bore. 13. A fiberoptic connector assembly as described in claim 11 wherein said fiberoptic connector includes a generally tubular metallic core member being disposed within said fiberoptic connector and forming said optical fiber bore; said fiberoptic connector also including a housing portion being disposed to surround and engage said core member;   a tip portion of said core member projecting forwardly from said housing member;   an optical fiber being disposed within said optical fiber bore and projecting to said tip portion;   said tip portion being deformed about said optical fiber to frictionally   
     
     
        engage said optical fiber. 14. A fiberoptic connector assembly device as described in claim 13 wherein said tip . .potion.!. .Iadd.portion .Iaddend.is deformed in a radially symmetrical manner, such that said optical fiber is engaged in a centrally disposed location relative to said 
     
     
        optical fiber bore. 15. A fiberoptic connector assembly device as described in claim 13 wherein a portion of said core member is disposed to project rearwardly from said housing member, and said rearwardly projection portion of said core member is crimped to mechanically engage 
     
     
        said optical fiber disposed therewithin. 16. A fiberoptic connector assembly device as described in claim 15, further including a sleeve member being engaged to said rearwardly projecting portion of said core member, said sleeve member enclosing portions of said optical fiber and a jacket covering of said optical fiber therewithin; said sleeve member being crimped to frictionally engage said rearwardly projecting portion of said core member and said jacket portion of said   
     
     
        optical fiber. .Iadd.17.  The method of claim 1, further comprising crimping a rearward portion of the fiberoptic connector about the optical fiber to mechanically engage the optical fiber therewithin. .Iaddend..Iadd.18. The method of claim 1, further comprising inserting a sleeve member around a rearward portion of the fiberoptic connector such that the sleeve member substantially surrounds at least a portion of the optical fiber, and crimping the sleeve member about the rearward portion of the fiberoptic connector and about the portion of the optical fiber to mechanically join a portion of the optical fiber to a portion of the rearward portion of the fiberoptic connector. .Iaddend..Iadd.19. The method of claim 1 wherein a tapered surface is applied to mechanically deform the deformable portion. .Iaddend..Iadd.20. The method of claim 1 wherein a substantially conically-shaped surface is applied to mechanically deform the deformable portion. .Iaddend..Iadd.21. The method of claim 1 wherein the deformable portion is mechanically deformed such that it substantially surrounds at least a portion of the optical fiber. .Iaddend..Iadd.22. A fiberoptic connector made by the method of claim 21. .Iaddend..Iadd.23. A fiberoptic connector made by the method of claim 1. 
     
     
        .Iaddend..Iadd.24.  A device adapted for making a fiberoptic connector with a deformable portion deformed against at least a portion of an optical fiber, comprising: a fiberoptic connector holder adapted to hold a fiberoptic connector and an optical fiber during use;   an engaging surface including a tip having a tapered opening; and   a movement system adapted to move the tip of the engaging surface and the deformable portion of a fiberoptic connector in relationship to one another, the movement being with enough force to deform the deformable portion against at least a portion of an optical fiber during use such that the optical fiber is frictionally adhered to the fiberoptic connector, wherein the deformable portion comprises a metal, and wherein the deformable portion is substantially uniformly swaged around the portion of the optical fiber. .Iaddend..Iadd.25. The device of claim 24 wherein the movement system includes a handle coupled to a lever, the lever being in turn coupled to the engaging surface and the handle and lever being adapted to move the engaging surface when the handle is manually operated during use. .Iaddend..Iadd.26. The device of claim 24, further comprising a frame the engaging surface and the fiberoptic connector holder being coupled to the frame during use. .Iaddend..Iadd.27. The device of claim 25 wherein the opening on the tip of the engaging surface is substantially conically shaped. .Iaddend..Iadd.28. The device of claim 24 wherein the fiberoptic connector holder is adapted to hold a portion of an optical fiber in a substantially central location within a bore of the fiberoptic connector during use. .Iaddend..Iadd.29. The device of claim 24 wherein the fiberoptic connector holder is adapted to hold the fiberoptic connector, and an optical fiber within the fiberoptic connector, in a substantially stationary position while the engaging surface is pressed against the fiberoptic connector during use. .Iaddend..Iadd.30. The device of claim 29 wherein the fiberoptic connector holder includes a stop that is adapted to engage the fiberoptic connector during use such that the fiberoptic connector does not move when pressed by the engaging surface during use. .Iaddend..Iadd.31. The device of claim 24 wherein the engaging surface is slidably engaged on a rail such that the engaging surface is in alignment with a tip of a fiberoptic connector during use. .Iaddend..Iadd.32. The device of claim 24, further comprising a fiberoptic connector being held by the fiberoptic connector holder, the fiberoptic connector including an optical fiber disposed within it. .Iaddend..Iadd.33. The device of claim 24 wherein the device is adapted to join a fiberoptic connector and an optical fiber together without use of a liquid adhesive. .Iaddend.