Fiber optic connector, fiber optic connector and cable assembly, and methods for manufacturing

Abstract

A fiber optic cable and connector assembly including a fiber optic connector mounted at the end of a fiber optic cable. The fiber optic connector includes a ferrule assembly including a stub fiber supported within a ferrule. The stub fiber is fusion spliced to an optical fiber of the fiber optic cable at a location within the fiber optic connector.

1 . (canceled) 
     
     
         2 . A method of manufacturing an optical fiber assembly comprising:
 preparing a stub fiber including terminating the stub fiber at a ferrule assembly, the ferrule assembly including a ferrule carried by a first hub portion that includes a first material;   splicing an optical cable fiber to the stub fiber at a splice location;   mounting a shell to the first hub portion so that the splice location is disposed within an interior of the shell;   injecting a second material into the interior of the shell to surround the splice location and to contact part of the first hub portion, the second material being different from the first material; and   curing the second material to solidify the second material, the second material cooperating with the shell to define a second hub portion that is attached to the first hub portion.   
     
     
         3 . The method of  claim 2 , wherein mounting the shell to the first hub portion includes inserting an end of the shell into the first hub portion. 
     
     
         4 . The method of  claim 2 , wherein mounting the shell to the first hub portion includes sliding the shell laterally over the optical cable fiber so that the optical cable fiber passes through a slot defined in the shell. 
     
     
         5 . The method of  claim 4 , wherein injecting the second material into the interior of the shell includes injecting the second material through a side port that is separate from the slot. 
     
     
         6 . The method of  claim 5 , wherein the side port is defined by the shell. 
     
     
         7 . The method of  claim 2 , wherein curing the second material includes heating the second material. 
     
     
         8 . The method of  claim 2 , wherein curing the second material includes transmitting UV light towards the second material. 
     
     
         9 . The method of  claim 8 , wherein transmitting UV light towards the second material includes transmitting UV light through the shell. 
     
     
         10 . The method of  claim 2 , wherein the first hub portion defines flat faces; and wherein the method further comprises:
 determining a core offset direction of the ferrule assembly; and   providing a core offset identifier on one of the flat faces.   
     
     
         11 . The method of  claim 2 , further comprising assembling a plug connector around the ferrule assembly. 
     
     
         12 . The method of  claim 11 , wherein assembling a plug connector includes:
 positioning a spring about the second hub portion; and   mounting a plug connector body about the ferrule assembly and the spring.   
     
     
         13 . The method of  claim 12 , wherein mounting the plug connector body comprises sandwiching the spring and the ferrule assembly between a front connector body and a rear connector body. 
     
     
         14 . The method of  claim 11 , wherein the optical cable fiber is part of an optical cable that also includes a strength member. 
     
     
         15 . The method of  claim 14 , further comprising crimping the strength member to the plug connector. 
     
     
         16 . The method of  claim 15 , further comprising coupling a strain relief boot to the plug connector over a location at which the strength member is crimped to the plug connector. 
     
     
         17 . The method of  claim 11 , further comprising coupling a strain relief boot to the plug connector. 
     
     
         18 . The method of  claim 11 , wherein the stub fiber is one of a plurality of stub fibers; and wherein preparing the stub fiber includes terminating the plurality of stub fibers at the ferrule assembly. 
     
     
         19 . The method of  claim 18 , wherein the optical cable fiber is one of a plurality of optical cable fibers; and wherein splicing the optical cable fiber to the stub fiber comprises splicing the optical cable fibers to the stub fibers at the splice location. 
     
     
         20 . The method of  claim 11 , wherein a total length of the assembled plug connector is no more than 57 millimeters, the total length being measured from a front end of the ferrule to a rear end of a boot of the assembled plug connector. 
     
     
         21 . The method of  claim 1 , wherein the stub fiber has selected properties that are different than the cable fibers, and wherein the selected properties are designed to suppress modal interference.