High density multi-fiber ferrule for optical fiber connector

Abstract

A ferrule for a high density optical fiber connector, supporting a first set of optical fibers of a first fiber cable and a second set of optical fibers of a second fiber cable. The ferrule supports the first and second sets of optical fibers in at least one plane. In one embodiment, the first set of optical fibers are supported in a first row of open grooves, and the second set of optical fibers are supported in a second row of open grooves. The optical fibers in the first row are staggered with respect to the optical fibers of the second row. The ferrule comprises two halves, each having an open structure that has a row of open grooves precisely formed thereon in a plane. In another embodiment, the ferrule supports the first and second sets of optical fibers in a single row, in an alternating interleaving manner.

1 . A ferrule for supporting optical fibers in an optical fiber connector, comprising a body structured with open grooves to support a first set of optical fibers and a second set of optical fibers, and with partitions to separate adjacent optical fibers in the open grooves, wherein the optical fibers are bare with cladding exposed, wherein the body of the ferrule comprises a first part and a second part opposing each other and maintained in mating relationship to support the first and second sets of optical fibers, and wherein the first set of optical fibers are staggered with respect to the second set of optical fibers at opposing surfaces of the first part and the second part, wherein the partitions define walls of adjacent open grooves, such that each open groove receives an optical fiber without the optical fiber protruding above the groove. 
     
     
         2 . (canceled) 
     
     
         3 . The ferrule as in  claim 1 , wherein the first part and the second part of the ferrule correspond to a first ferrule halve and a second ferrule halve, respectively, wherein the first ferrule halve has a plurality of a first open grooves supporting the first set of optical fibers and the second ferrule halve has a plurality of second open grooves supporting the second set of optical fibers, wherein the first open groove and the second groove are defined on the opposing surfaces of the first part and the second part. 
     
     
         4 . The ferrule as in  claim 3 , further comprising a collar clamping on the first and second ferrule halves to maintain the first and second ferrule halves in mating configuration. 
     
     
         5 . The ferrule as in  claim 1 , wherein the ferrule is structured to support the first set of optical fibers in a first row of open grooves in a first plane and the second set of optical fibers in a second row of open grooves in a second plane different from the first plane. 
     
     
         6 . The ferrule as in  claim 5 , wherein the ferrule comprises a first set of open grooves supporting the first set of optical fibers, and a second set of open grooves supporting the second set of optical fibers. 
     
     
         7 . The ferrule as in  claim 6 , wherein the ferrule is structured such that the first set of optical fibers in the first plane are staggered with respect to the second set of optical fibers in the second plane. 
     
     
         8 . The ferrule as in  claim 6 , wherein the ferrule comprises a first ferrule halve and a second ferrule halve, wherein the first ferrule halve comprises the first set of open grooves supporting the first set of optical fibers, and the second ferrule halve comprises the second set of open grooves supporting the second set of optical fibers. 
     
     
         9 . The ferrule as in  claim 8 , wherein the first set of open grooves are defined on a first surface of the first ferrule halve, and the second set of open grooves are defined on a second surface of the second ferrule halve, wherein the first surface and the second surface are mated when the first ferrule halve and the second ferrule halve are assembled to form the ferrule. 
     
     
         10 . The ferrule as in  claim 9 , wherein the ferrule is structured such that the first set of optical fibers in the first plane are staggered with respect to the second set of optical fibers in the second plane. 
     
     
         11 . The ferrule as in  claim 6 , wherein the partitions comprise first partitions at the first surface and second partitions at the second surface, and wherein the ferrule is structured such that adjacent optical fibers in the first set of open grooves are separated by the first partitions at the first surface, and adjacent optical fibers in the second set of open grooves are separated by the second partitions at the second surface, wherein when the first surface and the second surface are mated, the first partition face the second set of open grooves and the second partitions face the first set of open grooves. 
     
     
         12 . The ferrule as in  claim 11 , wherein the first partitions include first flat portions at the first surface, and the second partitions include second flat portions at the second surface, wherein when the first surface and the second surface are mated, the first flat portions cover the second set of open grooves and the second flat portions cover the first set of open grooves. 
     
     
         13 . The ferrule as in  claim 1 , wherein the optical fibers each has a diameter D, wherein immediate adjacent terminating end sections of the first set of optical fibers have a centerline spacing of 2D, and the immediate adjacent terminating end sections of the second set of optical fibers have a centerline spacing of 2D. 
     
     
         14 . The ferrule as in  claim 13 , wherein the terminating end sections of the first and second sets of optical fibers are staggered such that the terminating end sections of immediate adjacent optical fibers of the first and second sets of optical fibers have a centerline spacing of D. 
     
     
         15 . A ferrule for supporting optical fibers in an optical fiber connector, comprising a body that comprises a first set of open grooves in a first plane to support a first set of optical fibers, and a second set of open grooves in a second plane different from the first plane to support a second set of optical fibers, wherein the first set of optical fibers are of a first fiber cable and the second set of optical fibers are of a second fiber cable, wherein the first fiber cable is separate from the second fiber cable, wherein each open groove receives an optical fiber without the optical fiber protruding above the open groove, and wherein the first set of open grooves are defined on a first surface at a perimeter of the body of the ferrule, and the second set of open grooves are defined on a second surface at the perimeter of the body of the ferrule. 
     
     
         16 . The ferrule as in  claim 15 , further comprising a frame covering the first and second surfaces. 
     
     
         17 . A ferrule for supporting optical fibers in an optical fiber connector, comprising a body structured with at least an open groove to support a first set of optical fibers and a second set of optical fibers, wherein the first set of optical fibers are of a first fiber cable and the second set of optical fibers are of a second fiber cable, wherein the first fiber cable is separate from the second fiber cable, wherein the optical fibers are bare with cladding exposed, wherein the first set of optical fibers are staggered with respect to the second set of optical fibers, and wherein the ferrule is structured such that the first set of optical fibers are staggered with respect to the second set of optical fibers with longitudinal axis of the first and second sets of optical fibers in a single plane. 
     
     
         18 . The ferrule as in  claim 17 , wherein the ferrule is structured such that the first set of optical fibers are interleaved with respect to the second set of optical fibers in the single plane, wherein the first and second sets of optical fibers are arranged side-by-side, with the optical fibers of the first set of optical fibers alternating with the optical fibers of the second set of optical fibers. 
     
     
         19 . The ferrule as in  claim 18 , wherein the ferrule is structured such that the alternating optical fibers are arranged to be touching side-by-side. 
     
     
         20 . The ferrule as in  claim 19 , wherein the ferrule comprises a first ferrule halve and a second ferrule halve, wherein the first ferrule halve and the second ferrule halve together define a wide flat opening sized to receive the first and second sets of optical fibers arranged side-by-side. 
     
     
         21 . The ferrule as in  claim 20 , wherein a first wide flat section is defined on a first surface of the first ferrule halve, and a second wide flat section second set of open grooves are defined on a second surface of the second ferrule halve, wherein the first wide flat section and the second wide flat section together define the wide flat opening in the ferrule to accommodate the first and second sets of optical fibers. 
     
     
         22 . The ferrule as in  claim 5 , wherein the ferrule is structured such that the first plane and the second plane are separate parallel planes. 
     
     
         23 . The ferrule as in  claim 1 , wherein the first set of optical fibers are of a first fiber cable and the second set of optical fibers are of a second fiber cable, wherein the first fiber cable is separate from the second fiber cable. 
     
     
         24 . An optical fiber connector, comprising:
 the ferrule as claimed in  claim 1 ; and   a housing supporting the ferrule.