Tooling and method for manufacturing a fiber optic array

Abstract

A fixture is for forming a fiber optic array that defines a plurality of discrete fibers extending from a spaced-apart arrangement to a consolidated arrangement wherein the fibers are layered next to each other for a further ribbonizing process. The fixture includes a pair of contact blades that are configured to slide along a direction transverse to the longitudinal axes of the fibers for consolidating the fibers.

What is claimed is: 
     
         1 . A fiber optic array, comprising:
 a plurality of optical fibers, each optical fiber including a buffer tube portion surrounding the optical fiber;   a substrate for supporting the plurality of optical fibers, the substrate defining a first end and a second end and a first outer edge and a second outer edge perpendicular to the first and second ends; and   a plurality of spaced-apart channels defined by the substrate, the channels defining parallel portions at the first end of the substrate, the spaced-apart channels provided in a stacked arrangement extending from the first outer edge to the second outer edge, wherein the spaced-apart channels define open top ends for receiving the optical fibers therein such that the parallel portions of the channels defined at the first end of the substrate are sized to frictionally receive and secure the buffer tube portions of the optical fibers without an additional structure covering top sides of the optical fibers;   wherein the plurality of optical fibers are positioned on the substrate such that the optical fibers extend from being spaced-apart via the channels to a consolidated arrangement wherein the fibers are layered next to each other, and wherein the plurality of optical fibers are positioned within the spaced-apart channels such that a majority of each optical fiber is uncovered along a length thereof as the optical fibers extend from the first end to the second end of the substrate.   
     
     
         2 . A fiber optic array according to  claim 1 , wherein the substrate is an insert configured to be removably placed within a fiber optic cassette. 
     
     
         3 . A fiber optic array according to  claim 1 , wherein the substrate is a one-piece substrate. 
     
     
         4 . A fiber optic array according to  claim 3 , wherein the plurality of spaced-apart channels are formed integrally with the one-piece substrate as a unitary structure. 
     
     
         5 . A fiber optic array according to  claim 1 , wherein the parallel portions of the spaced-apart channels at the first end of the substrate are straight parallel portions, wherein the spaced-apart channels also define curved rear portions for transitioning the optical fibers from the straight parallel portions inwardly away from the first and second outer edges toward a central portion of the substrate with minimum bend radius protection. 
     
     
         6 . A fiber optic array according to  claim 1 , wherein the substrate is configured such that the optical fibers at the channels extend outwardly from the channels to an exterior of the substrate to form pigtails that are terminated with fiber optic ferrules, wherein the substrate is configured to position the optical fibers therein such that the entirety of each of the fiber optic ferrules extends out past the first end of the substrate. 
     
     
         7 . A fiber optic array according to  claim 1 , further comprising a fiber clamp provided at the second end of the substrate, the fiber clamp securing the consolidated fibers at the second end of the substrate, wherein the fiber clamp is defined by a clip that is snap-fit interlocked to the substrate. 
     
     
         8 . A fiber optic array according to  claim 1 , wherein the optical fibers supported by the substrate are further secured to the substrate via at least one piece of adhesive tape. 
     
     
         9 . A method for forming a fiber optic array that defines a plurality of discrete fibers extending from a spaced-apart arrangement to a consolidated arrangement wherein the fibers are layered next to each other, the method comprising:
 laying the fibers within spaced-apart channels defined by a substrate that is provided as a removable insert of a fixture, the channels having parallel portions;   abutting and moving the fibers in a direction transverse to longitudinal axes of the fibers to consolidate the fibers;   securing together the fibers at both the spaced-apart portion of the array and the consolidated portion of the array; and   removing the substrate from the fixture after the spaced-apart portion and the consolidated portion of the fibers have been secured to the substrate.   
     
     
         10 . A method according to  claim 9 , wherein the fibers are placed within the channels such that portions thereof extend outwardly from the channels to form pigtails, wherein the pigtails are terminated with fiber optic ferrules. 
     
     
         11 . A method according to  claim 9 , wherein the plurality of discrete fibers define pairs of fibers, the method further comprising crossing over the fibers of each of the pairs to form crossed-over fibers before consolidating the fibers. 
     
     
         12 . A method according to  claim 11 , further comprising contacting both fibers of a given pair at a cross-over point by a vertical pin to move the cross-over point toward the channels defined on the fixture. 
     
     
         13 . A fixture for forming a fiber optic array that defines a plurality of discrete fibers extending from a spaced-apart arrangement to a consolidated arrangement, wherein the fibers are layered next to each other for a further securing process that keeps the fibers together, the fixture comprising:
 at least one contact blade that is configured to move on the fixture along a direction transverse to longitudinal axes of the plurality of discrete fibers for consolidating the fibers, the fixture further defining channels at a front end thereof for supporting the fibers in the spaced-apart arrangement, wherein the fixture includes a first clamp adjacent the front end of the fixture for keeping the fibers within the channels in the spaced-apart arrangement and a second clamp adjacent a rear end of the fixture for keeping the fibers against a bearing surface of the fixture for contact by the transversely moving contact blade.   
     
     
         14 . A fixture according to  claim 13 , wherein the second clamp is slidable in a direction from the rear end of the fixture toward the front end of the fixture. 
     
     
         15 . A fixture according to  claim 13 , wherein the channels define curved rear portions for transitioning the plurality of discrete fibers from the spaced-apart arrangement toward a consolidation point at which the fibers are to be layered next to each other for further securing to keep the fibers together. 
     
     
         16 . A fixture according to  claim 13 , wherein the channels are defined by a removable substrate that forms a part of the fiber optic array manufactured using the fixture. 
     
     
         17 . A fixture according to  claim 14 , wherein the second clamp defines a plurality of vertical pins, each pin positioned to be in between a given pair of fibers such that if the fibers of the given pair are crossed-over, the pin can contact both fibers of the given pair at a cross-over point and move the cross-over point toward the front end of the fixture.