WO2022192274A1

WO2022192274A1 - Bare optical fiber alignment system and device

Info

Publication number: WO2022192274A1
Application number: PCT/US2022/019365
Authority: WO
Inventors: David Donald Erdman; Danny Willy August Verheyden; Michael Aaron Kadar-Kallen
Original assignee: Commscope Technologies Llc
Priority date: 2021-03-08
Filing date: 2022-03-08
Publication date: 2022-09-15

Abstract

A fiber alignment device including a plurality of fiber alignment components that are assembled with one another. At least some of the fiber alignment components include a molded alignment substrate defining fiber alignment grooves. The fiber alignment device includes elastomeric material for biasing optical fibers into the alignment grooves.

Description

BARE OPTICAL FIBER ALIGNMENT SYSTEM AND DEVICE CROSS-REFERENCE TO RELATED APPLICATION This application is being filed on March 8, 2022 as a PCT International Patent Application and claims the benefit of U.S. Patent Application Serial No. 63/157,942, filed on March 8, 2021, the disclosure of which is incorporated herein by reference in its entirety. TECHNICAL FIELD The present disclosure relates generally to fiber optic connection components such as fiber optic connectors, fiber alignment devices and adapters. More particularly, the present disclosure relates to bare fiber alignment systems, devices, and methods. BACKGROUND Fiber optic communication systems are becoming prevalent in part because service providers want to deliver high bandwidth communication capabilities (e.g., data and voice) to customers. Fiber optic communication systems employ a network of fiber optic cables to transmit large volumes of data and voice signals over relatively long distances. Optical fiber connectors are an important part of most fiber optic communication systems. Fiber optic connectors allow two optical fibers to be quickly optically connected without requiring a splice. Fiber optic connectors can be used to optically interconnect two lengths of optical fiber. Fiber optic connectors can also be used to interconnect lengths of optical fiber to passive and active equipment. A typical fiber optic connector includes a ferrule assembly supported at a distal end of a connector housing. A spring is used to bias the ferrule assembly in a distal direction relative to the connector housing. The ferrule functions to support an end portion of at least one optical fiber (in the case of a multi-fiber ferrule, the ends of multiple fibers are supported). The ferrule has a distal end face at which a polished end of the optical fiber is located. When two fiber optic connectors are interconnected, the distal end faces of the ferrules abut one another and the ferrules are forced proximally relative to their respective connector housings against the bias of their respective springs. With the fiber optic connectors connected, their respective optical fibers are coaxially aligned such that the end faces of the optical fibers directly oppose one another. In this way, an optical signal can be transmitted from optical fiber to optical fiber through the aligned end faces of the optical fibers. For many fiber optic connector styles (LC, SC, MPO), alignment between two fiber optic connectors is provided with an intermediate fiber optic adapter. Another type of fiber optic connector can be referred to as a ferrule-less fiber optic connector. In a ferrule-less fiber optic connector, an end portion of an optical fiber corresponding to the ferrule-less fiber optic connector is not supported by a ferrule. Instead, the end portion of the optical fiber is a free end portion. Similar to the ferruled connectors described above, fiber optic adapters can be used to assist in optically coupling together two ferrule-less fiber optic connectors. Example ferrule-less fiber optic connectors and/or fiber optic adapters are disclosed by PCT Publication Nos. WO 2012/112344; WO 2013/117598; WO 2017/081306; WO 2016/100384; WO 2016/043922; and U.S. Patent Nos.8,870,466 and 9,575,272. SUMMARY Aspects of the present disclosure relates to fiber alignment systems, apparatuses/devices, and methods for aligning optical fibers of ferrule-less fiber optic connectors. In certain examples, the fiber alignment systems are configured to accommodate fiber optic connectors including at least one, two, four, eight, twelve, sixteen, twenty-four, thirty-two, forty-eight, or more optical fibers. While aspects of the present disclosure are particularly useful in systems for aligning sets of multiple optical fibers (e.g., systems for aligning the optical fibers of multi-fiber optical connectors) because of the ability to provide high optical connection densities, the features and advantages of the present disclosure are also applicable to systems for aligning single pairs of optical fibers (e.g., systems for aligning the optical fibers of single fiber optical connectors). Aspects of the present disclosure relate to a fiber alignment device for aligning optical fibers. The fiber alignment device includes a plurality of fiber alignment components that are adapted to be assembled together. The fiber alignment components each include a molded alignment substrate which includes a first major side and an opposite second major side. The molded alignment substrate defines a plurality of alignment grooves on the first major side and an elastomeric material molded at the second major side of the molded alignment substrate. The elastomeric material is less rigid than the molded alignment substrate. The fiber alignment components are assembled with the first major side of a first fiber alignment component opposing the second major side of a second fiber alignment component such that the elastomeric material of the second fiber alignment component is positioned to press the optical fibers in a biasing direction into the alignment grooves of the first fiber alignment component when the optical fibers are inserted in an axial direction into the alignment grooves of the fiber alignment components. The biasing direction is perpendicular with respect to the axial direction. In some examples, the elastomeric material has a durometer hardness in the range of 5-90 Shore A, or in the range of 5-60 Shore A, or in the range of 5-40 Shore A, or in the range of 5-30 Shore A. In some examples, the elastomeric material has a material composition that includes silicone rubber. In some examples, the silicone rubber includes at least partially cured liquid silicone rubber. In some examples, the molded alignment substrate has a material composition that includes plastic. In some examples the plastic includes thermoplastic. In some examples, the thermoplastic includes polycarbonate, polyphenylsufone or polyetherimide. In some examples, the elastomeric material includes a sheet of elastomeric material. In some examples, the second major side of the molded alignment substrate includes a receptacle for receiving the elastomeric material. In some examples, the molded alignment substrate includes an injection molding gate in fluid communication with the receptacle for use in injecting the elastomeric material into the receptacle, the injection molding gate extending through a thickness of the molded alignment substrate between the first and second major sides of the molded alignment substrate. In some examples, the elastomeric material includes grooves. In some examples, the grooves of the elastomeric material are oriented perpendicular with respect to the axial direction and the biasing direction. In some examples, the elastomeric material includes first and second sections of elastomeric material provided at the second major side of the molded alignment substrate, the first and second sections being separated from one another in the axial direction by a slot that defines a reservoir for receiving index matching gel. In some examples, the molded alignment substrates include stand-offs at the second major sides for defining minimum spacings between adjacent ones of the fiber alignment components when the fiber alignment components are assembled together in a stack. In some examples the fiber alignment components each include: a first dimension that extends along the axial dimension between opposite first and second ends of the fiber alignment component, a second dimension perpendicular to the first dimension that extends between opposite first and second minor sides of the fiber alignment component, and a third dimension that is perpendicular to the first and second dimensions that extends between the first and second major sides of the molded alignment substrate. In some examples, the first dimension is a length of the fiber alignment component, the second dimension is a width of the fiber alignment component and the third dimension is a thickness of the fiber alignment component. In some examples, the molded alignment substrate defines stacking sections that extend along the length of the fiber alignment component, wherein the stacking sections are separated by the width of the fiber alignment component, wherein the fiber alignment grooves extend along the length of the fiber alignment component from the first end to the second end of the fiber alignment component, and wherein the fiber alignment grooves are v-groves and are positioned between the stacking sections of the molded alignment substrate. In some examples, the rails include first registration features at the first major side of the molded alignment substrate and second registration features at the second major side of the molded alignment substrate, wherein the first and second registration features of adjacent ones of the fiber alignment components mate with each other when the fiber alignment components are assembled together in a stack to align the fiber alignment components with respect to one another. In some examples, the optical fibers include a first set of optical fibers inserted into the fiber alignment grooves through the first end of the fiber alignment component and a second set of optical fibers inserted into the fiber alignment grooves through the second end of the fiber alignment component, wherein tips of the first and second sets of optical fibers are aligned and oppose one another at a central fiber coupling region of the fiber alignment component. In some examples, index matching gel is provided at the central fiber coupling region. In another aspect, the present disclosure relates to a fiber alignment device for aligning optical fibers. The fiber alignment device includes a first and a second component that are assembled together. The first component has pressing members. The pressing members have first and second sides at opposite first and second major sides of the first component and an elastomeric layer at the second major side of the first component. The second component has a grooved side defining fiber alignment grooves. The first and second components are assembled together such that the grooved side of the second component opposes the second major side of the first component. Aspects of the present disclosure also relate to fiber alignment systems, apparatuses/devices, and methods for enhancing insertion loss performance relating to optical connection locations/interface between optical fibers. Aspects of the present disclosure relate to a method for aligning optical fibers. The method includes biasing the optical fibers into alignment grooves using an elastomeric material either directly or indirectly. In some examples, the elastomeric material is a rubber material. In some examples, the elastomeric material is a silicone rubber material. In some examples, the elastomeric material is adapted to directly contact the optical fibers. In other examples the elastomeric material applies the biasing force indirectly to the optical fibers by one or more pressing members. In another aspect, the present disclosure relates to an alignment device for aligning optical fibers. The device includes a structure defining a fiber alignment groove; and an elastomeric material positioned provide biasing force for biasing optical fibers desired to be aligned by the alignment groove against an alignment feature of the fiber alignment groove. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is an isometric view of a fiber alignment device in accordance with the principles of this disclosure shown aligning sets of optical fibers; Figure 2 is a top view of the fiber alignment device of Figure 1; Figure 3 is a schematic cross-sectional view of an adapter featuring the fiber alignment device of Figure 1; Figure 4 is a cross-sectional view of the fiber alignment device of Figure 2 taken along section B-B; Figure 5 is an exploded view showing two of the fiber alignment components of the fiber optic alignment device of Figure 1 and also showing two sets of optical fibers adapted aligned by the interaction of the fiber alignment components; Figure 6 is a bottom exploded view of the fiber alignment components and optical fibers of Figure 5; Figure 7 is a cross-sectional view of the fiber optic components of Figures 5 and 6 cut lengthwise through optical fibers being aligned by the fiber optic components; Figure 8 is a set of alternative fiber alignment components in accordance with the principles of this disclosure; Figure 9 is a plan view of the fiber alignment components of Figure 8; Figure 10 is a schematic cross-sectional view of one of the fiber alignment components of Figure 8; Figure 11 is a cross-section of another fiber alignment device in accordance with the principles of the present disclosure, the fiber alignment device includes a plurality of the sets of fiber alignment components of Figure 8; and Figure 12 is a cross-sectional view of another fiber alignment device in accordance with the principles of the present disclosure. DETAILED DESCRIPTION Aspects of the present disclosure relate to alignment systems for aligning optical fibers of ferrule-less (e.g., bare fiber) fiber optic connectors to provide optical connections between the optical fibers of the fiber optic connectors. Aspects of the present disclosure additionally apply to the alignment of optical fibers of single optical fiber connectors and multi-fiber optical connectors. Alignment systems in accordance with the principles of the present disclosure include alignment structures for co-axially aligning optical fibers to provide optical connections between the aligned optical fibers. The alignment structures in some embodiments, define alignment grooves for receiving and aligning the optical fibers. In some examples, the alignment grooves are defined by structures such as substrates which may each define one or more grooves. The substrates can include members such as plates which may have a ceramic construction, a metal construction, a plastic construction or other constructions. The alignment grooves can include grooves having v-shaped cross- sections (e.g., v-grooves) grooves having u-shaped cross-sections, grooves having trough- shaped cross-sections, grooves having half-circle shaped cross-sections or grooves having other shapes. In other examples, the alignment grooves are defined by parallel cylindrical rods oriented in a side-by-side relationship. Various alignment structures defining grooves are disclosed by PCT International Publication Number WO 2018/020022, and PCT International Publication Number WO2020/112645 which are both hereby incorporated by reference in their entirety. In certain examples, index matching gel is used between opposing ends of optical fibers aligned within the alignment structures. In some examples, alignment systems in accordance with the principles of the present disclosure include contact or pressing elements (i.e., contact members, contact components, contact features, pressing members, pressing components, pressing features, etc.) that function to bias optical fibers into the alignment structures to ensure effective co- axial alignment of the optical fibers at the optical interface where end faces of the optical fibers oppose one another. Each contact or pressing element can include an element that is moveable relative to the alignment structure and that is configured to press first and second optical fibers within the alignment structure. A single one of the contact elements is preferably configured to press both of its corresponding first and second optical fibers into an alignment groove. The contact element preferably engages each of the first and second optical fibers directly at or in close proximity to tips of the optical fibers. In certain examples, each pressing member can be configured to press a single set of first and second optical fibers into a corresponding alignment groove or can be configured to press multiple sets of first and second fibers into corresponding alignment grooves. Referring to Figures 1 and 2, a fiber alignment device 20 for aligning optical fibers 112 is shown. The fiber alignment device 20 includes a plurality of fiber alignment components 100 that are arranged in a stacked relationship. The fiber alignment device 20 is shown aligning a first set of optical fibers 112a with a second set of optical fibers 112b such that each optic fiber of the first set of optical fibers 112a is co- axially aligned with a corresponding optical fiber of the second set of optical fibers 112b. The optical fibers 112a are axially inserted into a first end 150 of the fiber alignment device 20, and the optical fibers 112b are axially inserted into a second end 152 of the fiber alignment device 20, opposite to the first end 150. The fiber alignment components 100 are shown assembled with one another (e.g., in a vertically stacked relationship). Each of the fiber alignment components 100 includes a molded alignment substrate 102. Each of the molded alignment substrates 102 includes a first major side 104 and an opposite second major side 106. The molded alignment substrates 102 each define a plurality of alignment grooves 108 on the first major side 104. Each of the fiber alignment components 100 include an elastomeric material 110 molded at the second major side 106 (see Figure 4). The elastomeric material 110 is less rigid than the molded alignment substrate 102. Figure 3 is a schematic cross-sectional view of a fiber optic adapter 6 including the fiber alignment device 20. The fiber optic adapter 6 includes an adapter housing 12 which contains the fiber alignment device 20. The adapter housing 12 includes ports 6a, 6b for receiving fiber optic connectors 8a, 8b. The fiber optic connectors 8a, 8b include multi-fiber ferrule-less fiber optic connectors carrying optical fibers 112a, 112b with bare fiber portions including front ends 10 adapted to protrude forwardly from a connector body, shroud or other structure of the connectors when connectors are secured within a port 6a, 6b of the fiber optic adapter 6. The fiber alignment device 20 is housed within the adapter and configured to receive and align the front ends 10 of the bare fiber portions of the optical fibers 112a, 112b when the fiber optic connectors 8a, 8b are secured within their respective ports 6a, 6b. In certain examples the bare fiber portions and the front ends 10 protrude at least 2, 3, 4, 5, or 6 millimeters forwardly beyond the connector bodies or shrouds and into the fiber alignment device 20 when the connectors are installed in the ports 6a, 6b. In some examples, optical fibers 112a are inserted in a first axial direction D1 into the fiber alignment device 20 with the fiber optic connector 8a as the fiber optic connector 8a enters the port 6a. Similarly, the optical fibers 112b are inserted in a second axial direction D2 into the fiber alignment device 20 with the fiber optic connector 8b as the fiber optic connector 8b enters the port 6b. The axial directions D1 and D2 are opposite from one another and the optical fibers 112a, 112b. The front ends 10 of the optical fibers 112a, 112b meet at a central fiber coupling region in the middle of the fiber alignment device 20 at line B. During insertion into the fiber alignment device 20, the optical fibers 112a, 112b are forced/biased in a biasing direction D3 into the alignment grooves 108 at the first major sides 104 by the elastomeric material 110 at the second major sides 106 of the molded alignment substrates 102. In the depicted embodiment, the elastomeric material 110 directly contacts the optical fibers 112a, 112b and directly applies biasing load to the optical fibers 112a, 112b. The optical fibers 112a, 112b are co- axially aligned with respect to each other by the alignment grooves 108. The biasing direction D3 is perpendicular with respect to the axial directions D1 and D2 and is perpendicular to length directions of the alignment grooves 108. Figure 4 is a cross-sectional view of the fiber alignment device 20 taken along section B-B of Figure 2. A first fiber alignment component 100a, a second fiber alignment component 100b, a third fiber alignment component 100c and a fourth fiber alignment component 100d are depicted. The fiber alignment components 100a-100d are assembled such that the first major sides 104 of the fiber alignment components 100b- 100d oppose the second major sides 106 of the fiber alignment components 100a-100c, respectively. In this way, the elastomeric material 110 at the second major sides 106 of the fiber alignment components 100a-100c is positioned to press or bias the optical fibers 112a, 112a in the biasing direction D3 into the alignment grooves 108 of the of the respective (e.g., adjacent, corresponding, opposing) fiber alignment components 100b- 100d when the optical fibers 112a, 112b are inserted into the fiber alignment device 20. It is within the scope of this disclosure for there to be more or fewer fiber alignment components 100 than depicted. In a preferred example, the elastomeric material 110 includes grooves 111 (see Figure 7) which are perpendicular to both the biasing direction D3 and the axial directions D1, D2. Thus, the grooves 111 are transversely oriented with respect to the directions of insertion of the optical fibers 112a, 112b. The grooves 111 can be configured to reduce/tune/control/adjust the resistance provided by the elastomeric material 110 (e.g., rubber) as the optical fibers 112a, 112b are inserted axially into the alignment grooves 108. The elastomeric material 110 preferably adheres to the molded alignment substrate 102. In certain examples, an additive or additives in the elastomeric material 110 can enhance adhesion with the molded alignment substrate 102. In certain examples, fillers can be included in the elastomeric material 110 to change the coefficient of friction of the elastomeric material 110 to control or adjust the insertion force required to insert the optical fibers 112 axially into the alignment grooves 108 while being engaged by the elastomeric material 110. In some examples, the elastomeric material 110 has a durometer hardness in the range of 5-90 shore A, or in the range of 5-60 Shore A, or in the range of 5-40 Shore A or in the range of 5-30 Shore A. In some examples, the elastomeric material 110 has a material composition that includes silicone rubber. The silicone rubber is preferably at least partially cured liquid silicone rubber. The elastomeric material 110 preferably includes elastomeric material 110 having a sheet-like layer construction. The molded alignment substrates 102 are molded with a material composition that includes plastic, the plastic preferably includes a thermoplastic (e.g., polycarbonate, polyphenylsufone or polyetherimide). In certain examples, cross-linking in the elastomeric material 110 provides the elastomeric material 110 with relatively low compression set properties. Examples materials, such as silicone rubbers or fluoro-rubbers or other materials having compression sets less than 30, 25, 20, 15 or 10 (e.g., when tested after 100 hours of compression pursuant to ASTM D395 Standard Test Methods for Rubber Property – Compression Set) can be used to make the elastomeric material 110. While low compression set materials are preferred, for certain applications, other materials having elastomeric properties can be used as well. In certain examples, a generally flat configuration of the elastomeric material is used to reduce horizontal alignment sensitivity and allows the alignment components to have a thin construction such that the alignment device as a compact configuration in the stacking orientation. Additionally, in some examples, the elastomeric material 110 is molded within the molded alignment substrates 102, allowing for minimization of part count of the alignment device and assembly of the alignment device to be simplified. Figures 5 and 6 respectively depict upper and lower exploded views of an adjacent set/pair of the fiber alignment component 100a, 100b. The second major sides 106 of the molded alignment substrates 102 of the fiber alignment components 100a, 100b are shown including receptacles 126 (see Figure 6) for receiving the elastomeric material 110. Each of the molded alignment substrates 102 of the fiber alignment components 100a, 100b also includes an injection molding gate 128 which is in fluid communication with the receptacle 126 of the second major side 106. The injection molding gate 128 allows for the elastomeric material 110 to be injection molded through the thickness of the molded alignment substrate 102 into the receptacle 126 during manufacture of the fiber alignment components 100a, 100b. The injection molding gates 128 extend through a thickness of each molded alignment substrate 102 between the first and major sides 104, 106. The molded alignment substrates 102 each include stacking features allowing the molded alignment substrates 102 to stack on one another in registration with one another. As can easily be seen in Figures 5 and 6, the molded alignment substrates 102 include registration notches 102a (e.g., corner notches) on the first major sides 104 adapted to mate with registration projections 102b (e.g., corner projections such as corner posts) on the second major sides 106. In this way, the molded alignment substrates 102 can stack in alignment with one another to create fiber alignment devices in accordance with the principles of the present disclosure. Fiber alignment devices for use with connectors having different fiber counts can be manufactured by stacking different numbers of molded alignment substrates 102 with one another. The molded alignment substrates 102 additionally can include stand-offs 102c. The stand-offs 102c define minimum spacings between the adjacent fiber alignment components 100 when the fiber alignment components 100 are stacked on one another. The stand-offs 102c work to ensure that spacings between molded alignment substrates 102 which are adjacent are maintained above minimum spacings required for the optical fibers 112 to be inserted into the alignment grooves 108. In a preferred example, the stand-offs 102c are provided at the second major sides 106 of the molded alignment substrates 102. Thus, the stand-offs 102c are not on the same sides of the molded alignment substrates 102 as the grooves 111. Instead, the stand-offs 102c and the alignment grooves 108 are on opposite sides of the molded alignment substrates 102. This is advantageous as eliminating the stand-offs 102c from the same side of the molded alignment substrate 102 as the alignment grooves 108 allows for using processes such as diamond turning to make the alignment grooves 108. In certain examples, the stand-offs 102c have a tapered transverse cross-sectional shape to enhance robustness. For example, the stand-offs 102c can be molded with a draft angle. The stand-offs 102c can each include side surfaces that extend along the lengths of the stand-offs 102c and that converge as the side surfaces extend away from the molded alignment substrate 102. The stand-offs 102c can have lengths parallel to lengths of the alignment grooves 108. In some examples, the elastomeric material 110 includes first and second sheet sections 110a, 110b located at the second major side 106 of the molded alignment substrate 102. The first and second sheet sections 110a, 110b are separated in the axial direction by a slot 110c (seen at Figure 6 and 7). The slot 110c is configured to receive an index matching gel and corresponds to a fiber coupling region where the optical fibers 112a, 112b are coupled together optically. The index matching gel matches the index of refraction of the optical fibers 112 and allows for reductions in Fresnel loss when the optical fibers 112 meet in the fiber alignment device 20. Each of the fiber alignment components 100 includes a length dimension L, a width dimension W and a thickness dimension T that are perpendicular with respect to one another. The length dimension L is parallel to the grooves 111 and the thickness dimension T extends between the first and second major sides 104, 106. The length dimension L extends between opposite ends 150, 152 of the molded alignment substrate 102 and the width dimension W extends between minor sides 154, 156 of the molded alignment substrate 102. Stacking sections 158, 160 are located adjacent the minor sides 154, 156 and extend along the length dimension L. The stacking sections 158, 160 are separated by the width dimension W and do not include the alignment grooves 108. Instead, substrate registration features (e.g., registration notches 102a and registration projections 102b) are provided at the stacking sections 158, 160. Injection molding gates 128 are provided through the stacking sections 158. Figure 8 depicts another fiber alignment device 300 in accordance with the principles of the present disclosure. Like the previously described embodiment, the fiber alignment device 300 is adapted for coaxially aligning sets of optical fibers. In this embodiment, an elastomeric material is used to indirectly apply biasing load to optical fibers by transferring the biasing load/force though intermediate pressing structures such as flexible beams to the optical fibers desired to be aligned. The biasing load/force from the pressing members can bias the optical fibers into alignment structures such as fiber alignment grooves 322 (e.g., v-grooves or other grooves). The fiber alignment device 300 includes a first alignment component 302 and a second alignment component 304 that are assembled with one another (e.g., stacked) to form the fiber alignment device 300. The first fiber alignment component 302 includes a molded substrate 303 including a plurality of pressing members 306 (e.g., flexible beams such as elastic beams (see Figure 9). The pressing members 306 have opposite first and second sides 308, 310 (see Figure 10) positioned at first and second opposite major sides 312, 314 of the molded substrate 303. The first sides 308 of the pressing members 306 are adapted to contact and apply biasing load to optical fibers inserted into the fiber alignment device 300. The first fiber alignment component 302 also includes an elastomeric layer 316 positioned at the second sides 310 of the pressing members 306 for assisting the pressing members 306 in applying biasing force to optical fibers inserted into the fiber alignment device 300 for alignment (e.g., the elastomeric layer 316 provides supplement biasing force transferred through the pressing members 306 to the optical fibers). The elastomeric layer 316 is positioned in a recess at the second major side 314 of the molded substrate 303. In a preferred example, the elastomeric layer 316 aligns with a central fiber coupling region of the fiber alignment device 300. The second alignment component 304 has a grooved side 320 having a plurality of fiber alignment grooves 322. The first and second alignment components 302, 304 are stacked together in registration with one another such that the grooved side 320 of the second alignment component 304 opposes the first major side 312 of the first alignment component 302. In the assembled configuration, the first sides 308 of the pressing members 306 oppose open sides of the fiber alignment grooves 322 such that when optical fibers are axially inserted into the fiber alignment grooves 322, the pressing members 306 with the assistance of the elastomeric layer 316 press the optical fibers against alignment surfaces of the fiber alignment grooves 322. In certain examples, an additional feature can be provided for containing the elastomeric layer 316 such that when the pressing members 306 flex in response to optical fibers being inserted into the fiber alignment grooves 322, the elastomeric layer 316 is pressurized and therefore resists flexing of the pressing members 306. In this way, the elastomeric layer 316 backs the pressing members 306 and complements the biasing forces applied by the pressing members 306 to the optical fibers for pressing the optical fibers into their corresponding fiber alignment grooves 322. In certain examples, the elastomeric layer 316 has a composition of the type previously described herein. For example, the elastomeric layer 316 can have a material composition that includes a silicone such as silicone rubber. In certain examples, the elastomeric layer 316 includes projections 317 (e.g., rails, see Figure 11) corresponding to each of the pressing members 306. The projections 317 are separated by slots 319 (see Figure 11) in the elastomeric layer 316 and have lengths that extend along the lengths of the pressing members 306. Figure 11 depicts another fiber alignment device 300a in accordance with the principles of the present disclosure. The fiber alignment device 300a includes a plurality of the fiber alignment devices 300 stacked together to allow the fiber alignment device 300a to accommodate multiple rows of optical fibers. It will be appreciated that different fiber alignment devices 300 for accommodating different fiber counts can be made by assembling different numbers of the fiber alignment device 300. Figure 12 depicts a portion of another fiber alignment device 400 in accordance with the principles of the present disclosure that is similar to the fiber alignment device 300a, except pressing members 406 are each sized to coincide with more than one fiber alignment groove 422 and stand-offs 455 ensure that a minimum spacing is provided between aligned and assembled fiber alignment components 402, 404. The assembled fiber alignment components 402, 404 include the pressing members 406 and also includes elastomeric material 416 for providing biasing force to the pressing members 406. The fiber alignment components 402, 404 define the fiber alignment grooves 422. The fiber alignment components 402, 404 include the stand-offs 455 which are adapted to engage the grooved sides of the fiber alignment components 404. Thus, the stand-offs 455 are not integrated with the grooved sides of the fiber alignment components 404, but instead are provided on opposing sides of the assembled fiber alignment components 402, 404 which are adjacent to one another in the stack. In certain examples, the stand-offs 455 can be tapered as previously described herein. In certain examples, the stand-off features can be used in fiber alignment devices 400 having alternative biasing structures such as metal spring structures for applying biasing load to the pressing members 406.

Claims

CLAIMS What is claimed: 1. A fiber alignment device for aligning optical fibers, the fiber alignment device comprising: a plurality of fiber alignment components that are assembled together, at least some of the fiber alignment components each including: a molded alignment substrate including a first major side and an opposite second major side, the molded alignment substrate defining a plurality of fiber alignment grooves at the first major side; an elastomeric material molded at the second major side of the molded alignment substrate, the elastomeric material being less rigid than the molded alignment substrate; and the fiber alignment components being assembled with the first major side of a first one of the fiber alignment components opposing the second major side of a second one of the fiber alignment components such that the elastomeric material of the second one of the fiber alignment components is positioned to press the optical fibers in a biasing direction into the alignment grooves of the first one of the fiber alignment components when the optical fibers are inserted in an axial direction into the alignment grooves of the first one of the fiber alignment components, wherein the biasing direction is perpendicular with respect to the axial direction.

2. The fiber alignment device of claim 1, wherein the elastomeric material has a durometer hardness in the range of 5-90 Shore A, or in the range of 5-60 Shore A, or in the range of 5-40 Shore A, or in the range of 5-30 Shore A.

3. The fiber alignment device of claim 1 or 2, wherein the elastomeric material has a material composition that includes silicone rubber.

4. The fiber alignment device of claim 3, wherein the silicone rubber includes at least partially cured liquid silicone rubber.

5. The fiber alignment device of any of claims 1-4, wherein the molded alignment substrate has a material composition that includes plastic.

6. The fiber alignment device of claim 5, wherein the plastic includes thermoplastic.

7. The fiber alignment device of claim 6, wherein the thermoplastic includes polycarbonate, polyphenylsufone or polyetherimide.

8. The fiber alignment device of any of claims 1-7, wherein the elastomeric material includes a sheet of elastomeric material.

9. The fiber alignment device of any of claims 1-7, wherein the second major side of the molded alignment substrate includes a receptacle for receiving the elastomeric material.

10. The fiber alignment device of claim 9, wherein the molded alignment substrate includes an injection molding gate in fluid communication with the receptacle for use in injecting the elastomeric material into the receptacle, the injection molding gate extending through a thickness of the molded alignment substrate between the first and second major sides of the molded alignment substrate.

11. The fiber alignment device of any of claims 1-7, wherein the elastomeric material includes grooves.

12. The fiber alignment device of claim 11, wherein the grooves of the elastomeric material are oriented perpendicular with respect to the axial direction and the biasing direction.

13. The fiber alignment device of any of claims 1-7, wherein the elastomeric material includes first and second sections of elastomeric material provided at the second major side of the molded alignment substrate, the first and second sections being separated from one another in the axial direction by a slot that defines a reservoir for receiving index matching gel.

14. The fiber alignment device of any of claims 1-7, wherein the molded alignment substrates include stand-offs at the second major sides for ensuring that a minimum spacing is defined between adjacent ones of the fiber alignment components when the fiber alignment components are assembled together in a stack.

15. The fiber alignment device of claim 14, wherein the stand-offs have lengths parallel to lengths of the alignment grooves and have tapered transverse cross-sectional profiles.

16. The fiber alignment device of any of claims 1-7, wherein the fiber alignment components each include: a first dimension that extends along the axial dimension between opposite first and second ends of the fiber alignment component; a second dimension perpendicular to the first dimension that extends between opposite first and second minor sides of the fiber alignment component; and a third dimension perpendicular to the first and second dimensions that extends between the first and second major sides of the molded alignment substrate.

17. The fiber alignment device of claim 16, wherein the first dimension is a length of the fiber alignment component, the second dimension is a width of the fiber alignment component and the third dimension is a thickness of the fiber alignment component.

18. The fiber alignment device of claim 17, wherein the molded alignment substrate defines stacking sections that extend along the length of the fiber alignment component, wherein the stacking sections are separated by the width of the fiber alignment component, wherein the fiber alignment grooves extend along the length of the fiber alignment component from the first end to the second end of the fiber alignment component, and wherein the fiber alignment grooves are v-groves and are positioned between the stacking sections of the molded alignment substrate.

19. The fiber alignment device of claim 18, wherein the stacking sections include first registration features at the first major side of the molded alignment substrate and second registration features at the second major side of the molded alignment substrate, wherein the first and second registration features of adjacent ones of the fiber alignment components mate with each other when the fiber alignment components are assembled together in a stack to align the fiber alignment components with respect to one another.

20. The fiber alignment device of claim 18, wherein the optical fibers include a first set of optical fibers inserted into the fiber alignment grooves through the first end of the fiber alignment component and a second set of optical fibers inserted into the fiber alignment grooves through the second end of the fiber alignment component, wherein tips of the first and second sets of optical fibers are aligned and oppose one another at a central fiber coupling region of the fiber alignment component.

21. The fiber alignment device of claim 20, wherein index matching gel is provided at the central fiber coupling region.

22. A fiber alignment device for aligning optical fibers, the fiber alignment device comprising: first and second components that are assembled together; the first component having pressing members, the pressing members having first and second sides at opposite first and second major sides of the first component; the first component also having an elastomeric layer at the second major side; the second component having a grooved side defining fiber alignment grooves; the first and second components being assembled together such that the grooved side of the second component opposes the first major side of the first component.

23. The fiber alignment device of claim 22, wherein the elastomeric layer has a material composition that includes silicon and is configured to apply a biasing force to the pressing members.

24. The fiber alignment device of claim 23, wherein the biasing force is in a direction towards the grooved side of the second component.

25. The fiber alignment device of claim 22, wherein the elastomeric layer includes at least partially cured liquid silicone rubber.

26. The fiber alignment device of claim 22, wherein the pressing members are configured to press optical fibers into the alignment grooves.

27. A method for aligning optical fibers, the method comprising: biasing the optical fibers into an alignment groove using an elastomeric material either directly or indirectly as the optical fibers are inserted axially into the alignment groove.

28. An alignment device for aligning optical fibers comprising: a structure defining a fiber alignment groove; and an elastomeric material positioned to provide biasing force for biasing optical fibers desired to be aligned by the alignment groove against an alignment feature of the alignment groove as the optical fibers are inserted axially into the alignment groove.

29. The alignment device of claim 28, wherein the elastomeric material has a rubber construction.

30. The alignment device of claim 28, wherein the elastomeric material has a silicone rubber construction.

31. The alignment device of any of claims 28-30, wherein the elastomeric material is adapted to directly contact the optical fibers.

32. The alignment device of any of claim 28-30, wherein the elastomeric material applies the biasing force indirectly to the optical fibers by one or more pressing members.

33. A fiber alignment device for aligning optical fibers, the fiber alignment device comprising: first and second components that are assembled together; the first component having pressing members, the pressing members having first and second sides at opposite first and second major sides of the first component; the first component also having stand-offs integrated at the first major side; the second component having a grooved side defining fiber alignment grooves; the first and second components being assembled together such that the grooved side of the second component opposes the first major side of the first component and the stand-offs ensure that a minimum spacing is maintained between the grooved side of the second component and the first major side of the first component.

34. The fiber alignment device of claim 33, wherein the stand-offs have lengths that are parallel to lengths of the fiber alignment grooves, and wherein the stand-offs have tapered transverse cross-sectional profiles.

35. The fiber alignment device of claim 34, wherein the tapered transverse cross- sectional profiles are defined by surfaces that converge as the surfaces extend away from the first major side of the first component toward the grooved side of the second component.