Methods for centering optical fibers inside a connector ferrule and optical fiber connector

Abstract

An optical fiber connector assembly includes at least one ferrule, the ferrule having a front end, at least one bore for receiving at least one optical fiber, and an optical fiber at least partially disposed in the bore, at least a portion of the at least one optical fiber being disposed in the at least one ferrule bore so that a section of the at least one fiber portion has an end face that is essentially even with the ferrule front end, a section of the optical fiber having a bulge which has a size which is larger than the bare optical fiber diameter, the fiber at least partially contacts a surface of the ferrule bore, and the contact defining a fiber-to-ferrule interface region. The fiber-to-ferrule interface region includes substantial contact between the bulge and a portion of the surface of the bore such that movement of the fiber in the bore is inhibited and the remaining portion of the optical fiber is substantially centered in the at least one bore.

1 . An optical fiber connector assembly with at least one ferrule, the ferrule having a front end at least one bore for receiving at least one optical fiber, and an optical fiber at least partially disposed in the bore, said assembly comprising:
 at least a portion of the at least one optical fiber is disposed in the at least one ferrule bore so that a section of the at least one fiber portion has an end face that is essentially even with the ferrule front end, a section of the optical fiber comprising a bulge which has a size which is larger than the bare optical fiber diameter, the fiber at least partially contacts a surface of the ferrule bore, and the contact defining a fiber-to-ferrule interface region; and   
       the fiber-to-ferrule interface region comprises substantial contact between the bulge and a portion of the surface of the bore whereby movement of the fiber in the bore is inhibited. 
     
     
         2 . The assembly of  claim 1 , wherein the interface region comprises a force-fit aligning the at least one optical fiber in the bore. 
     
     
         3 . The assembly of  claim 1 , wherein the bulge is has a size of about 25 μm to about 50 μm larger than the bare fiber diameter, and the fiber end face is essentially flat. 
     
     
         4 . The assembly of  claim 1 , wherein the optical fiber includes collapsed void regions and void regions that have not been collapsed, and the fiber end face protrudes from the ferrule front end. 
     
     
         5 . The assembly of  claim 1 , wherein the substantial contact comprises a bulge size being larger than a ferrule bore inside diameter, thereby causing a tight fit. 
     
     
         6 . The assembly of  claim 1 , wherein the bulge has a size of up to about 0.8% larger than the bare fiber diameter. 
     
     
         7 . The assembly of  claim 1 , wherein the size associated with the bulge is about 0.8% to about 20% larger compared to the bare fiber diameter. 
     
     
         8 . The assembly of  claim 1 , wherein the size associated with the bulge is about 2% to about 5% larger compared to the bare fiber diameter. 
     
     
         9 . The assembly of  claim 1 , wherein the ferrule includes an epoxy material and the optical fiber is at least partially bonded to the ferrule by the epoxy.