Multifiber ferrule

Abstract

A ferrule assembly comprising: (a) an array of optical fibers each having a mating end face; and (b) a ferrule with the fibers disposed therein, the ferrule having a front and rear orientation and a front surface, the front surface having at least a mating surface and a non-mating surface, the mating surface extending forward beyond the non-mating surface and presenting the mating end face of at least one of the fibers.

1. A ferrule assembly comprising:
 an array of optical fibers each having a mating end face; and  
 a ferrule with said fibers disposed therein, said ferrule having a front and rear orientation and a front surface, said front surface having at least a mating surface and a non-mating surface, said mating surface extending forward beyound said non-mating surface and presenting the mating end face of at least one of said fibers.  
 
   
   
     2. The ferrule assembly of  claim 1 , wherein the area of said mating surface is no greater than about 50% of the area of said front surface. 
   
   
     3. The ferrule assembly of  claim 2 , wherein the area of said mating surface is no greater than about 30% of the area of said front surface. 
   
   
     4. The ferrule assembly of  claim 3 , wherein the area of said mating surface is no greater than about 20% of the area of said front surface. 
   
   
     5. The ferrule assembly of  claim 1 , wherein said mating surface is planar. 
   
   
     6. The ferrule assembly of  claim 1 , wherein said front surface is curved and said mating surface is at the apex of the curve. 
   
   
     7. The ferrule assembly of  claim 1 , wherein said mating surface is planar and said non-mating surface is curved. 
   
   
     8. The ferrule assembly of  claim 1 , wherein said mating surface is planar and said non-mating surface is planar. 
   
   
     9. The ferrule assembly of  claim 8 , wherein said mating surface and said non-mating surface are on parallel planes. 
   
   
     10. The ferrule assembly of  claim 1 , wherein the perimeter of said mating surface is surrounded by said non-mating surface. 
   
   
     11. The ferrule assembly of  claim 1 , wherein said mating surface presents the ends of all of said fibers. 
   
   
     12. The ferrule assembly of  claim 1 , wherein said front surface comprises two or more mating surfaces. 
   
   
     13. The ferrule assembly of  claim 12 , wherein each mating surface comprises a single fiber. 
   
   
     14. An optical connector comprising:
 a housing;  
 a ferrule assembly in said housing, said ferrule assembly comprising: 
 an array of optical fibers each having a mating end face; and  
 a ferrule with said fibers disposed therein, said ferrule having a front and rear orientation and a front surface, said front surface having at least a mating surface and a non-mating surface, said mating surface extending forward beyond said non-mating surface and presenting the mating end face of at least one of said fibers.  
 
 
   
   
     15. A method of manufacturing a ferrule assembly comprises the steps of:
 providing a ferrule comprising a body having a front and rear orientation and a front surface and openings for holding said array of fibers and presenting the ends of said fibers for mating;  
 forming a mating surface and a non-mating surface on said front surface, said mating surface extending forward beyond said non-mating surface and presenting the mating end face of at least one of said fibers.  
 
   
   
     16. The method of  claim 15 , further comprising:
 fixing optical fibers in said openings prior to forming said mating surface.  
 
   
   
     17. The method of  claim 16 , wherein forming said mating and non-mating surfaces comprises at least the steps of
 polishing said ferrule to form a curved front surface;  
 polishing said curved front surface to form said mating surface.  
 
   
   
     18. The method of  claim 17 , wherein forming said curved front surface is performed using a compliant polishing wheel. 
   
   
     19. The method of  claim 18 , wherein forming said mating surface is performed using a substantially non-compliant polishing wheel.