Field-installable fusion spliced fiber optic connector kits and methods therefor

Abstract

A field-installable fusion fiber optic connector kit and methods of assembling the same include a ferrule block subassembly and a splice, cover handling block subassembly. The ferrule block subassembly includes a fiber optic stub, a ferrule, and a disposable ferrule handling block. The ferrule has a longitudinal bore therethrough for holding the fiber optic stub so that an end of the fiber optic stub extends beyond the ferrule. The disposable ferrule handling block is used for holding the ferrule during the assembly process. The splice cover handling block subassembly includes a crimp body, a spring, a splice cover, and a disposable splice cover handling block. The disposable splice cover handling block is used for holding the crimp body, the spring, and the splice cover during the assembly process.

1 . A field-installable fusion optical fiber connector kit comprising: 
 a ferrule block subassembly comprising: 
 a fiber optic stub;  
 a ferrule, the ferrule having a longitudinal bore therethrough, wherein the fiber optic stub is held in the longitudinal bore and an end of the fiber optic stub extends beyond the ferrule; and  
 a disposable ferrule handling block, the disposable ferrule handling block being used for holding the ferrule during the assembly process; and  
   a splice cover handling block subassembly comprising: 
 a crimp body;  
 a spring;  
 a splice cover, the splice cover having a first end and a second end and a longitudinal passage between the first end to the second for housing a fusion splice of the fiber optic stub; and  
 a disposable splice cover handling block, wherein the disposable splice cover handling block is used for holding the crimp body, the spring, and the splice cover during the assembly process.  
   
   
   
       2 . The fiber optic connector kit according to  claim 1 , the disposable splice cover handling block having a first end and a second end, the first end of the disposable splice cover handling block having a plurality of resilient fingers that act as a stop for the second end of the splice cover.  
   
   
       3 . The fiber optic connector kit according to  claim 1 , the ferrule having an outer diameter of about 1.25 millimeters.  
   
   
       4 . The fiber optic connector kit according to  claim 1 , further comprising a connector housing.  
   
   
       5 . The fiber optic connector kit according to  claim 1 , further comprising a connector housing and a trigger, wherein the trigger attaches to the connector housing.  
   
   
       6 . The fiber optic connector kit according to  claim 1 , further comprising a container for housing and protecting the ferrule block subassembly prior to assembly of the fiber optic connector.  
   
   
       7 . The fiber optic connector kit according to  claim 1 , the ferrule being held by a first end of the disposable ferrule handling block so that the fiber optic stub extends therefrom.  
   
   
       8 . The fiber optic connector kit according to  claim 1 , the splice cover having at least one aperture for filling the longitudinal passageway.  
   
   
       9 . The fiber optic connector kit according to  claim 1 , the fiber optic connector being connected to a portion of a cable.  
   
   
       10 . A ferrule block subassembly comprising: 
 a fiber optic stub;    a ferrule, the ferrule having a longitudinal bore therethrough, wherein the fiber optic stub is held in the longitudinal bore and an end of the stub extends beyond the ferrule; and    a disposable ferrule handling block, the disposable ferrule handling block being used for holding the ferrule during the assembly process.    
   
   
       11 . The ferrule block subassembly according to  claim 10 , the ferrule having an outer diameter of about 1.25 millimeters.  
   
   
       12 . The ferrule block subassembly according to  claim 10 , further comprising a container for housing and protecting the ferrule block subassembly prior to assembly of the fiber optic connector.  
   
   
       13 . The ferrule block subassembly according to  claim 12 , the container having a living hinge.  
   
   
       14 . A splice cover handling block subassembly comprising: 
 a crimp body;    a spring;    a splice cover, the splice cover having a first end and a second end and a longitudinal passage between the first end to the second for housing a fusion splice of the fiber optic stub; and    a disposable splice cover handling block, wherein the disposable splice cover handling block is used for holding the crimp body, the spring, and the splice cover during the assembly.    
   
   
       15 . The splice cover handling block subassembly according to  claim 14 , the disposable splice cover handling block having a first end and a second end, the first end of the disposable splice cover handling block having a plurality of resilient fingers that act as a stop for the second end of the splice cover.  
   
   
       16 . The splice cover handling block subassembly according to  claim 14 , the splice cover having at least one aperture for filling the longitudinal passageway.  
   
   
       17 . A field-installable fusion optical fiber connector kit comprising: 
 a ferrule block subassembly comprising: 
 a fiber optic stub;  
 a ferrule, the ferrule having a longitudinal bore therethrough, wherein the fiber optic stub is held in the longitudinal bore and an end of the fiber optic stub extends beyond the ferrule; and  
 a disposable ferrule handling block, the disposable ferrule handling block being used for holding the ferrule during the assembly process;  
   a splice cover handling block subassembly comprising: 
 a crimp body;  
 a spring;  
 a splice cover, the splice cover having a first end and a second end and a longitudinal passage between the first end to the second for housing a fusion splice of the fiber optic stub; and  
 a disposable splice cover handling block, wherein the disposable splice cover handling block is used for holding the crimp body, the spring, and the splice cover during the assembly process; and  
   a container for housing and protecting the ferrule block subassembly so that the end of the fiber optic stub that extends beyond the ferrule is not damaged prior to assembly of the fiber optic connector.    
   
   
       18 . The fiber optic connector kit according to  claim 17 , the disposable splice cover handling block having a first end and a second end, the second end of the disposable splice cover handling block having a plurality of resilient fingers that act as a stop for the first end of the splice cover.  
   
   
       19 . The fiber optic connector kit according to  claim 17 , the ferrule having an outer diameter of about 1.25 millimeters.  
   
   
       20 . The fiber optic connector kit according to  claim 17 , further comprising a connector housing.  
   
   
       21 . The fiber optic connector kit according to  claim 17 , further comprising a connector housing and a trigger, wherein the trigger attaches to the connector housing.  
   
   
       22 . The fiber optic connector kit according to  claim 17 , the ferrule being held by a first end of the disposable ferrule handling block so that the fiber optic stub extends therefrom.  
   
   
       23 . The fiber optic connector kit according to  claim 17 , the splice cover having at least one aperture for filling the longitudinal passageway.  
   
   
       24 . The fiber optic connector kit according to  claim 17 , the fiber optic connector being connected to a portion of a cable.  
   
   
       25 . A method of assembling a field-installable fusion optical fiber connector comprising: 
 supplying a ferrule block subassembly, the ferrule block subassembly comprising a ferrule having a fiber optic stub, wherein the fiber optic stub is held in a longitudinal bore of the ferrule and an end of the fiber optic stub extends beyond the ferrule, and a disposable ferrule handling block, the disposable ferrule handling block being used for holding the ferrule during the assembly process;    supplying a splice cover handling block subassembly, the splice cover handling block subassembly comprising a crimp body, a spring, a splice cover, and a disposable splice cover handling block, the disposable splice cover handling block is used for holding the crimp body, the spring, and the splice cover during the assembly process;    supplying an optical fiber for splicing with the fiber optic stub;    fusion splicing the fiber optic stub and the optical fiber;    removing the disposable ferrule handling block from the ferrule block subassembly before a final assembly of the optical fiber connector; and    removing the disposable splice cover handling block from the splice protector block subassembly before a final assembly of the optical fiber connector.    
   
   
       26 . The method of  claim 25 , wherein the ferrule has an outer diameter of about 1.25 millimeters.  
   
   
       27 . The method of  claim 25 , further comprising the step of removing the ferrule block subassembly from a container that houses and protects the ferrule block subassembly prior to assembly of the fiber optic connector.  
   
   
       28 . The method of  claim 25 , further comprising supplying a connector housing and a trigger, wherein the connector housing attaches to the crimp body and the trigger attaches at least to to the connector housing.