US20110312249A1

US20110312249A1 - Optical fiber polishing apparatus and method

Info

Publication number: US20110312249A1
Application number: US13/148,815
Authority: US
Inventors: James R. Bylander; Tomoyasu Oike; Takaya Yamauchi; Steven G Lucht; Kent E. Lageson
Original assignee: 3M Innovative Properties Co
Current assignee: 3M Innovative Properties Co
Priority date: 2009-03-17
Filing date: 2010-02-22
Publication date: 2011-12-22
Also published as: WO2010107552A2; CN102356339B; WO2010107552A3; JP2012521021A; CN102356339A

Abstract

A hand-held polishing apparatus is provided for polishing an optical fiber connector. The optical fiber connector mounted on the end of an optical fiber includes a connector housing and a ferrule. The polishing apparatus includes a connector mount to receive and hold the optical connector to position the end face of the ferrule adjacent to a polishing media. The polishing apparatus includes a housing having an upper portion and a base portion, a drive assembly and a lubricant dispensing system. The drive assembly controls orbital movement of the optical connector and linear movement of the polishing media through the polishing device, and the lubricant dispensing system supplies a lubricant from an internal reservoir disposed with in the housing to the polishing media near the end face of the ferrule of the optical connector.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention
The present invention is directed to an apparatus and method for polishing an optical fiber, in particular, an optical fiber terminated and polished in the field.
2. Background
In the area of optical telecommunication networks, fiber optic connectors are one of the primary ways to connect two or more optical fibers. There are several classes of optical fiber connectors including adhesive ferruled connectors, in which the fiber tip is held in a substantially fixed position relative to the tip of the ferrule by adhesively securing the fiber within the bore of the ferrule. Another class of connectors includes non-ferrule connectors, which rely on the buckling of a length of fiber to create contact force. Another class of connectors includes remote grip (ferruled) connectors, where the fiber is secured at some distance away from the terminal end or tip of the fiber.
When installing a remote grip connector in the field, one current practice uses a coplanar/flush polish. In remote grip connectors, as with other connector types, low optical losses and minimal reflections are achieved when the terminal ends of at least two optical fibers make secure physical contact. However, any differences in the coefficient of expansion between the fiber and the ferrule assembly may result in a non-contacting fiber tip when the temperature is raised, or lowered. The resulting gap can lead to significant reflection. A conventional remote grip connector is described in U.S. Pat. No. 5,408,558.
Another current practice involves a technician performing a field polish to create a fiber terminal end which protrudes beyond the ferrule tip. This method of polishing remote grip connectors produces a range of protrusions that provide a secure physical contact while avoiding excess force on the fiber tips. This method, when carefully followed, allows sufficient physical contact of the at least two fiber terminal end faces at temperatures for indoor applications (0° C. to 60° C.). However, the conventionally polished field-terminated remote grip connector may not be recommended for outdoor use, which has more stringent temperature requirements (−40° C. to 80° C.). Factors leading to unacceptable optical loss may result from the intrinsic variability of the field polishing process, craftsman error, over polishing (e.g. using too much force or too many strokes and coarse, clogged or contaminated abrasive) or substitution of a different type of abrasive.
The following references describe conventional devices for polishing optical fibers: US 2003/0139118 A1; US 2004/0086251 A1; US 2008/0119111 A1; U.S. Pat. No. 3,975,865; U.S. Pat. No. 4,178,722; U.S. Pat. No. 4,291,502; U.S. Pat. No. 4,979,334; U.S. Pat. No. 5,007,209; U.S. Pat. No. 5,185,966; U.S. Pat. No. 5,216,846; U.S. Pat. No. 5,349,784; and U.S. Pat. No. 5,351,445.

SUMMARY

According to an exemplary aspect of the present invention, a hand-held polishing apparatus is provided for polishing an optical fiber connector. The optical fiber connector includes a connector housing and a ferrule. The optical connector is mounted on the end of an optical fiber. The polishing apparatus includes a connector mount to receive and hold the optical connector to position the end face of the ferrule adjacent to a polishing media. The polishing apparatus includes a housing having an upper portion and a base portion, a drive assembly and a lubricant dispensing system. The drive assembly controls orbital movement of the optical connector and linear movement of the polishing media through the polishing device, and the lubricant dispensing system supplies a lubricant from an internal reservoir disposed within the housing to the polishing media near the end face of the ferrule of the optical connector.
In another exemplary aspect of the present invention, a hand-held polishing apparatus is provided for polishing an optical fiber connector which uses a tape-style polishing media. The optical fiber connector, which is mounted on an end of an optical fiber, includes a connector housing and a ferrule. The polishing apparatus includes a connector mount to receive and hold the optical connector to position the end face of the ferrule adjacent to the tape-style polishing media. The polishing apparatus includes a housing having an upper portion and a base portion and a drive assembly. The drive assembly controls orbital movement of the optical connector and linear movement of the tape-style polishing media through the polishing device.
According to another exemplary aspect of the present invention, a method of polishing an optical connector comprises providing an optical fiber having a stripped terminal end. The optical fiber is inserted through a connector body and a ferrule. A protrusion of the fiber tip from an end face of the ferrule is set. The optical fiber is secured in the optical connector. The optical connector is mounted in a connector mount of a polishing apparatus. The polishing apparatus includes a housing having an upper portion and a base portion, a drive assembly and a lubricant dispensing system. The method further includes dispensing a lubricant using the lubricant dispensing system. The lubricant is supplied from an internal reservoir disposed within the housing to the polishing media near the end face of the ferrule of the optical connector. Activation of the drive assembly initiates the polishing of the fiber tip protruding from the end face of the ferrule. The drive assembly controls orbital movement of the optical connector and linear movement of the polishing media through the polishing device causing the protruding fiber tip to travel a predetermined distance against the polishing media. Further, the exposed fiber can be cleaved either prior to setting the protrusion of the fiber from the end face of the ferrule or after the fiber is secured in the optical connector.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be further described with reference to the accompanying drawings, wherein:

FIGS. 1A and 1B show two alternate isometric views of an exemplary polishing apparatus according to an aspect of the present invention.

FIG. 2A is a sectional view of an exemplary polishing apparatus of FIG. 1A.

FIG. 2B is a cross-sectional view of an exemplary polishing apparatus of FIG. 1A.

FIG. 3 is an exploded view of the drive assembly of an exemplary polishing apparatus according to an aspect of the present invention.

FIG. 4 is an isometric view showing a connector holder plate disposed in an upper portion of the housing of an exemplary polishing apparatus according to an aspect of the present invention.

FIG. 5 is an isometric cut-away view showing the media dispenser disposed in a base portion of the housing of an exemplary polishing apparatus according to an aspect of the present invention.

FIGS. 6A-6D is a top view showing how the orbital movement of the connector holding plate results in the pivoting of the bell crank which moves the polishing media in a linear direction.

FIG. 7 is a view of an exemplary polishing pattern according to an aspect of the present invention.

FIG. 8 is an exploded view of an exemplary optical connector which can be polished with the exemplary polishing apparatus of the present invention.

While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE EMBODIMENTS

In the following Detailed Description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. In this regard, directional terminology, such as “top,” “bottom,” “front,” “back,” “leading,” “forward,” “trailing,” etc., is used with reference to the orientation of the Figure(s) being described. Because components of embodiments of the present invention can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is in no way limiting. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims.
The present invention is directed to an apparatus and method for polishing an optical fiber terminated in an optical fiber connector. As described herein, a simple method of field polishing and assembly of an optical connector can provide consistent, repeatable results and can substantially reduce the craft sensitivity, when contrasted with traditional field polishing methods, and can reduce connector installation costs. In a preferred aspect, the polishing apparatus can be a lightweight, hand-held, mechanical device that is operated manually in the field.
FIGS. 1A and 1B show an exemplary polishing apparatus 100. The polishing apparatus 100 includes a connector mount 120 and an elongated housing 110 including a base portion 114 and an upper portion 112 that can fit comfortably in one hand during the polishing process. Within the housing, polishing apparatus includes a drive assembly 150, lubricant dispensing system 130 and a media dispenser 140 as shown in FIGS. 2A and 2B.
The upper and lower portions of the housing can be joined together by known mechanical means such as by mechanical fasteners, latches or clips. In the exemplary embodiment shown in FIGS. 1A and 1B, the upper and base portions 112, 114 of the housing may be joined by placing four screws (not shown) through a tab 112 a extending from the upper portion 112 of the housing 110 and into a threaded socket 114 a on the base portion 114 of the housing wherein the tab 112 a is aligned with the threaded socket 114 a when assembled together. Alternatively, the upper portion and the lower portion may be hingedly attached at the backside to facilitate replacement of the polishing media and reduce the number of mechanical fasteners needed to hold the upper portion of the housing and the lower portion of the housing together.
The polisher housing 110 can be constructed from a rigid material, such as a metal or a molded polymer (e.g., a glass or mineral filled plastic). In a preferred aspect, apparatus 100 is lightweight (e.g., less than 1 lbs., more preferably less than 0.5 lbs.) and can be held securely in one hand during operation.
In use, a connector 10 is inserted into the connector mount 120 of the polishing apparatus. A lubricant supplied by the lubricant dispensing system 130 from an internal reservoir 132 can be applied to the polishing media 142 near the connector tip. The drive assembly 150 can be actuated to create the polishing motion used to polish the end face of the fiber held by the optical connector 10. The pattern 199 of the polishing motion is one in which the optical connector moves in a circular orbit, represented by arrow 199 a, while the polishing media 142 moves in a generally linear movement, represented by arrow 199 b, and is shown in FIG. 7.
Referring to FIGS. 2-4, the drive assembly 150 is responsible for controlling the orbital motion of the optical connector and the linear motion of the polishing media during a polishing operation. The drive assembly 150 can be disposed in the upper portion 112 of the housing 110. The upper portion of the housing can be divided into two chambers 115 a and 115 b by support wall 112 c. The first chamber 115 a can have a lid or cover 112 b to allow access to the first chamber 115 a for installation and/or maintenance of the drive assembly components contained therein.
In an exemplary embodiment, the power to drive the polishing mechanism can be provided by pulling on a string 151 attached to drive assembly 150. String 151 is wrapped around a spool 152 within the drive assembly which is attached to a first one way drive plate 153. A flat wound spring, not shown, retracts the string as the user releases the tension on it causing it to wrap back around the spool in preparation for the next polishing operation.
When assembled, wedge shaped projections 153 a (FIG. 3) on the first one way drive plate 153 engage with wedge shaped projections 154 a on a second one way drive plate 154. The drive apparatus is mounted to a support wall 112 c within the upper portion 112 of polisher housing 114, such that when string 151 is pulled, the second drive plate 154 and drive shaft 155 are rotated. When the tension on the string is released, the mating wedge shaped projections 153 a, 154 a of the first and second drive plates 153, 154 slip over one another. Thus, the second drive plate and drive shaft do not rotate in a backwards direction when the spring is released.
Drive shaft 155 passes through support wall 112 c where it connects to the center gear 156 c in a three gear set 156. The three gear set 156 includes the center gear 156 c, a first side gear 156 a positioned on one side of the center gear and a second side gear 156 b located on a second side of the center gear opposite the first gear. In an exemplary embodiment, the first and second side gears 156 a, 156 b are the same size and turn in unison when the center gear 156 c rotates. Each of the first and second side gears has an off- center stub 157 a, 157 b projecting from a lower side gear surface as shown in FIGS. 2A and 3. These stubs 157 a, 157 b can engage with receptacles 161 a, 161 b on connector holding plate 160 causing the connector mount 120 disposed on the connector holding plate to move in an orbital motion. In an exemplary embodiment, the diameter of the orbital motion can be about 0.5 in.
The motion of the connector holding plate 160 activates the media dispenser 140 to mete out the polishing media 142 from a storage roll 142 a in a controlled manner. Media dispenser 140 may be disposed within base portion 114 of the polisher housing 110 and dispenses polishing media 142 as shown in FIGS. 2A and 2B. Media dispenser 140 can include a container portion 141 to hold or otherwise support roll 142 a of polishing media 142. Alternatively, the polishing apparatus can be configured to implement single-use strips of polishing media.
Referring to FIG. 2A, the polishing media 142 can be in the form of a strip. The strip can come in the form of a roll 142 a which will allow multiple polishing operations to be completed before the roll needs to be replaced. Alternatively, the polishing media comprises a single use strip which must be replaced each time a new connector is polished. To simplify changing the polishing media, the roll of polishing media may be held in a disposable container. The polishing media may comprise an abrasive material formed on a backing having a grit size from about 0.02 μm to about 2 μm. Alternatively, the polishing media can include a first course abrasive material for doing a course polish and a second finer abrasive material for doing the final polish, each occupying a particular section of the polishing media. The polishing media selected can depend on a number of factors including the application in which the connector will be used, the type of finish needed, and the type of connector being polished. A single media such as 2 μm aluminum oxide could be used for multimode connectors typically used in local area networks. Single mode connectors with more stringent specifications may require finer grit sizes or even multiple grit sizes of abrasive material to obtain the necessary finish on the end of the fiber. The backing can be formed from paper or a polymer film material such as a polyester film. For example, the polyester film can have a thickness of about 3 mil (0.08 mm). In an exemplary single mode polishing process, a 0.02 μm silicon dioxide abrasive on a 3 mil polyester film (863XW 3M™ Final Polish, available from 3M Company, St. Paul, Minn.) or a 0.05 μm aluminum oxide abrasive on a 3 mil polyester film (263XW 3M™ Lapping Film AO Type P, also available from 3M Company, St. Paul, Minn.) can be used. While in an exemplary multimode polishing process, a 2 μm aluminum oxide abrasive on a 2 mil polyester film backing (254X 3M™ Lapping Film AO Type R3, available from 3M Company, St. Paul, Minn.) can be used.
The roll of polishing media can be replaced by separating the upper portion 112 and the base portion 114 of the housing 110. The spent disposable container can be removed from the media dispenser 140 and replaced with a new one including a roll 142 a of the appropriate polishing media 142. A length of the polishing media 142 can be pulled out of the new container and routed over spring loaded pressure plate assembly 149 before the upper portion 112 and the base portion 114 of the housing 110 are reassembled.
Connector plate 160 interacts with tabs 143 a, 143 b on either side of bell crank 143 causing the bell crank to pivot back and forth as shown in FIGS. 5 and 6A-D. Bell crank 143 is pivotally attached to a lower portion 114 of the housing 110 by pin 145. A pawl 146 is attached to bell crank 143 on either side at points 146 a, 146 b. As the bell crank pivots to one side, one of the pawls is pushed forward while the other is pulled back. When the pawl 146 is pulled back, a hook 146 c on the end of the pawl engages with a tooth on ratchet 147 a on the side of a lower nip roller 147 which causes the polishing media 142 to be meted out in a direction 148 when it is squeezed between the lower nip roller 147 and an upper nip roller 147 b (FIG. 2A) mounted in the upper portion 112 of housing 110. As the bell crank pivots back in the opposite direction, the forward pawl moves back and the rearward pawl on the opposite side of the bell crank moves forward.
FIGS. 6A-6D show a more detailed view of how the movement of the connector holding plate 160 causes the bell crank 143 to pivot from side to side. FIG. 6A shows the connector holding plate positioned in an arbitrary centered forward position relative to the housing 110. As the gear set (not shown) rotates, the connector holding plate 160 can move in a clockwise orbit as shown by the trace of the polishing pattern 199 shown in FIG. 7. As the connector plate rotates to the 3 o'clock position (FIG. 6B), the connector holding plate 160 contacts tab 143 b which extends from one of the arms 143 c of bell crank 143 causing it to pivot in a direction 144 b. As the connector holding plate 160 continues its orbit through the 6 o'clock position (FIG. 6C) and to the 9 o'clock position (FIG. 6D), the connector holding plate 160 contacts tab 143 a which extends from the second arm 143 d of bell crank 143 causing it to pivot in a direction 144 a. The back and forth motion of the bell crank results in the controlled meting out of the polishing media as described previously.
During polishing, the polishing media 142 is supported by a spring loaded pressure plate assembly 149 (see FIG. 2A) to assure the proper contact force between the terminal end of the optical fiber and the polishing media.
The spring loaded pressure plate assembly includes a compliant layer 149 a, a floating rigid base plate 149 b, a hollow support shaft 149 e, a solid support shaft 149 c and a spring 149 d. One end of the hollow support shaft 1493 is fixedly attached to the rigid base plate 149 b while the other end of the hollow support shaft 149 e is placed over a solid support shaft 149 c that is fixedly attached to the base portion 114 of the polisher housing 110. The outer diameter of solid support shaft 149 c is slightly smaller than the inner diameter of hollow support shaft 149 e, allowing hollow support shaft 149 e, and therefore the rest of spring loaded pressure plate assembly 149, to slide telescopically up and down solid support shaft 149 c. The spring 149 d is sized such that it fits over both support shafts 149 c and 149 e and is constrained at its ends against rigid base plate 149 b and base portion 114, providing the lifting pressure for the spring loaded pressure plate assembly 149. Compliant layer 149 a can comprise a relatively hard material (e.g., having a Shore A durometer of about 60 to about 80, preferably a Shore A durometer of about 70). The spring force of the spring 149 d provides overall compliance for the spring loaded pressure plate assembly 149 while the compliant layer 149 a provides the appropriate support for the polishing media 142.
In a further exemplary aspect, the appropriate contact force on the fiber tip being polished can be from about 100 grams force to about 150 grams force, preferably about 130 grams force, depending on the length of the protruding fiber and the abrasive media. The combination of contact force, compliance of the spring loaded pressure plate assembly 149 and shape of the ferrule tip cooperate to help provide a desired shape on the polished fiber surface.
An additional feature of the dispenser system 140 is the cut-off blade 197 (see FIG. 2A) provided on the polishing apparatus. The cut-off blade 197 removes used portions of polishing media between polishing operations.
An additional feature of the exemplary polishing system is the integral lubricant dispensing system 130 housed within the polishing apparatus. The lubricant dispensing system 130 can supply a lubricant (not shown) to the polishing media 142 near the tip of the optical connector ferrule. Referring to FIGS. 2A, 2B and 4, the lubricant dispensing system 130 includes a reservoir 132 for holding a supply of the desired lubricant, a flexible tube 133 to guide the lubricant from the reservoir to the polishing media 142 and a pump 134 to deliver the lubricant. In an exemplary embodiment, the reservoir 132 can be located in a rearward section of the base portion 114 of the device housing 110. In an exemplary embodiment the pump 134 can be a small positive displacement pump such as a manually operated diaphragm pump, priming pump or plunger pump. For example, FIG. 2B shows a bulb style priming pump 134 disposed in the polishing device 100. To use, the craftsman presses on the external flexible bulb 134 on the outside of the device. The compression of the bulb 134 a moves the lubricant through a feed tube 134 b from the reservoir 132 to the polishing area through the flexible tube 133. The lubricant can exit the flexible tube 133 through orifice 165 (see FIG. 4) to fill the fluid distribution channels 166 adjacent the ferrule end face 15. Reservoir 132 has a filling port capped off with a fill plug 135 in the wall of the reservoir to accommodate easy filling of the reservoir with the lubricant. In an exemplary aspect, the lubricant can comprise DI water or another conventional polishing fluid.
As shown in FIG. 3, the connector mount 120 is disposed on connector holding plate 160. Connector mount 120 is configured to receive an optical fiber connector 10 therein. As described in further detail below, once the optical fiber connector is fully mounted in connector mount 120, the protruding fiber tip can be polished by activating the drive assembly which controls the polishing pattern that the tip of the ferrule traces on the polishing media.
The connector mount 120 is configured to receive a conventional optical fiber connector, such as an SC, LC, ST, FC or MT style connector. For example, a conventional connector can include a remote grip connector 10 (see e.g. FIG. 8). Such a connector 10 is described in detail in US Patent Publication No. 2008/0226236, incorporated by reference herein in its entirety. This exemplary connector 10 includes a fiber connector housing 312 and having an optical fiber terminated in the connector ferrule 332. When the optical fiber connector 10 is mounted in connector mount 120, the mount is configured to bring the ferrule face 15 and protruding fiber tip (not shown) into proximity of the polishing media 142 which is supported by a spring loaded pressure plate assembly 149. The connector mount 120 also secures the connector 10 in place to reduce potential movement caused by unintentional forces placed on the fiber cable or connector components. The structure of exemplary connector 10 and the polishing operation are described in more detail below. The optical cable can be a conventional cable such as a 250 μm or 900 μm buffer coated fiber, Kevlar reinforced jacketed fiber, or other sheathed and reinforced fibers.
In alternative aspects, the conventional connector 10 can include a Crimplok™ Connector available from 3M Company (St. Paul, Minn.), a 3M™ 8300 Hot Melt SC connector, or 3M™ 8206 FC/APC Connector (Epoxy) available from 3M Company (St. Paul, Minn.). In an exemplary aspect, the connector 10 can have an SC format. In other aspects, the polishing apparatus can be configured to receive a connector having another standard connector format, such as an LC format or an FC format. In a further alternative, the connector mount 120 can be configured to receive a connector having multiple fibers, such as an MT fiber connector.
The connector mount 120 is configured to releasably hold and secure optical fiber connector 10 and to provide a snug fit to hold connector 10, e.g., by a snap fit. Preferably, connector 10 can be held by the connector mount 120 at a predetermined angle. For example, the connector mount 120 can hold connector 10 for a flat polish (0°), where the polishing media is perpendicular to the axial direction of the fiber, or, alternatively, an angled polish that is at a small angle (about 2° to about 12°) from perpendicular, to yield an angle-polished connector.
In an alternative aspect, the string pull of the drive assembly can be replaced by a crank or a rotating knob. While in another alternative aspect, the polishing apparatus manually operated drive assembly can be replaced by an electric motor, at least one battery, and a control circuit. The electric motor would control the motion of the connector plate and the moving of the polishing media during operation in a method similar to that described above.
Advantageously, apparatus 100 can provide consistent, repeatable polishing results and can substantially reduce the craft sensitivity. The incorporation of the lubricant dispensing system eliminates the need for an external supply of lubricant. Also, the tape style polishing media allows the polishing apparatus to hold enough media to polish a plurality of optical connectors before the roll of media needs to be replaced, thus saving time and simplifying the polishing process.
An exemplary method of the present invention provides a repeatable process that can lead to repeatable field polishing or optical fiber connectors. In particular, the following method can be employed to effectuate one or more field polished optical fiber connectors in a straightforward manner. In an exemplary aspect, the overall process includes stripping and cleaving the fiber cable, setting the fiber protrusion (distance between the fiber tip and the ferrule end face, and polishing the fiber tip. After polishing, the fiber tip can be cleaned.
In more detail, a strain relief boot (see FIG. 8, boot 380) can be threaded onto the fiber cable onto which a remote grip-style optical connector is being installed. For thicker fiber jackets (e.g., 900 μm fibers), an additional crimp sleeve (not shown) can also be threaded onto the fiber prior to polishing. The connector 10 may be seated in an installation tool or other holder prior to cleaving. An appropriate length of optical fiber cable can be prepared by removing a terminal portion (e.g., ˜6 mm) of the cable jacket. The fiber can then be stripped of its buffer coating using a conventional fiber cable stripper such that the buffer coating extends about 0.5 inch beyond the cable jacket. The exposed glass tip portion can be cleaned using an alcohol (or other conventional cleaner) wipe.
The fiber can be positioned into a field cleaver, such as the cleaver described in PCT publication Number WO2008/100768, incorporated by reference herein in its entirety. A cleaving operation, using e.g., a diamond coated wire, can be performed using the field cleaver. This cleaver can produce a fiber tip having a cleave angle of between 0° to about 3.5° from perpendicular.
The cleaved fiber is then moved to a protrusion setting mechanism that sets the distance the fiber tip protrudes from the end face of the ferrule. At this stage, the fiber can be guided into the remaining connector components until the fiber tip protrudes from the ferrule end. In an exemplary aspect, the protrusion setting mechanism comprises a setting jig having a ferrule-type end with a fixed step formed thereon. The setting jig is brought into contact with the connector 10 so that the stepped end of the setting jig contacts the end of the connector ferrule. This process sets the proper protrusion distance to the point where a slight bow in the fiber assures that fiber contact with the setting jig is maintained. A sufficient protrusion can be from about 15 μm to about 35 μm, with a preferable protrusion of about 25 μm. With the remote grip connector, the gripping element is then actuated using the actuator cap to secure the fiber position. In addition, buffer strain relief is activated using the buffer clamp portion of the connector 10. Optionally, when utilized, a crimping tool can be used to compress the crimp sleeve around the fiber jacket to secure the fiber cable in place after the fiber protrusion setting.
In an alternative aspect of the invention the exposed end of the optical fiber may be cleaved after the optical fiber is secured in an optical connector, such as a Crimplok™ Connector available from 3M Company (St. Paul, Minn.).
The connector 10 is thus ready for polishing and can be inserted in connector mount 120 of the polishing apparatus 100. The polishing media (e.g., a 863XW 3M™ Final Polish, available from 3M Company, St. Paul, Minn.) can be wetted with a lubricant (e.g. DI water or other conventional polishing fluid) by pressing the compressible bulb 134 a (FIG. 2B) disposed on the polishing apparatus 100 so that the pump will deliver the lubricant from the reservoir 132 to the polishing media through an opening 165 (FIG. 4) in the connector holding plate 160 close the ferrule end face 15 of connector 10.
The craftsman can activate the polishing apparatus by pulling on an end pull string 151. Advantageously, the pull string can have a knob 151 a or other holder on an end thereof to facilitate gripping the string during polisher activation. This action activates the drive assembly 150 which creates moves the connector holding plate 160 in an orbital motion while simultaneously moving the polishing media in a linear direction. If additional polishing is needed, this process can be repeated. The degree of polish needed will determine the number of activation steps needed to complete the polishing operation. Factors such as the type of polishing media, connector style, and application need to be considered when determining the required degree of polish needed.
The exemplary embodiments described above can simplify the field polishing process, while controlling several sources of variability that have in the past led to a skill-level dominated practice. For example, the common “air polishing” practice of beginning a field polish while holding an abrasive polishing material in air (without any controlled backing force being applied) can be eliminated. Also, the field technician needs to be concerned the polishing force or polishing distance (e.g. the size and shape of figure 8's traced on the polishing media). The polishing apparatus can be a simple hand tool, without the need for a motor or power source. For certain connectors, such as described above, only a single polishing step would be needed.
The present invention should not be considered limited to the particular examples described above, but rather should be understood to cover all aspects of the invention as fairly set out in the attached claims. Various modifications, equivalent processes, as well as numerous structures to which the present invention may be applicable will be readily apparent to those of skill in the art to which the present invention is directed upon review of the present specification. The claims are intended to cover such modifications and devices.

Claims

1. A hand-held polishing apparatus for polishing an optical fiber connector, the optical fiber connector including a connector housing and a ferrule, comprising:

a connector mount to receive and hold the optical connector mounted on the end of an optical fiber wherein the end face of the ferrule is adjacent to a polishing media;

a housing having an upper portion and a base portion;

a drive assembly to control orbital movement of the optical connector and linear movement of the polishing media through the polishing device; and

a lubricant dispensing system to supply a lubricant from an internal reservoir disposed with in the housing to the polishing media near the end face of the ferrule of the optical connector.

2. The polishing apparatus of claim 1, further comprising a spring loaded pressure plate assembly to provide a contact force between the polishing media and a terminal end of the optical fiber when the optical connector is disposed in the connector mount

3. The polishing apparatus of claim 1, further comprising a polishing media dispenser disposed within the housing that contains a supply of tape style polishing media.

4. The polishing apparatus of claim 1, wherein the contact force is from about 100 grams force to about 150 grams force.

5. The polishing apparatus of claim 1, wherein the connector is held in the connector mount at a predetermined angle, the predetermined angle providing for one of a flat polish that is perpendicular to the longitudinal direction of the fiber and an angled polish.

6. The polishing apparatus of claim 5, wherein the angled polish comprises an angle from perpendicular of about 2° to about 12°.

7. The polishing apparatus of claim 1, wherein the drive assembly is string-activateable, wherein pulling on the string causes optical connector to trace a polishing pattern of a known length against the polishing media.

8. The polishing apparatus of claim 1, where in the optical fiber connector is a multi-fiber optical fiber connector.

9. The polishing apparatus of claim 1, wherein the drive assembly includes an electric motor, at least one battery, and a control circuit.

10. A hand-held polishing apparatus for polishing an optical fiber connector, the optical fiber connector including a connector housing and a ferrule, comprising:

a housing having an upper portion and a base portion;

a connector mount disposed within the housing to receive and hold the optical connector mounted on the end of an optical fiber wherein the end face of the ferrule is adjacent to a tape-style polishing media; and

a drive assembly to control orbital movement of the optical connector and linear movement of the polishing media through the polishing device.

11. The polishing apparatus of claim 10, further comprising a lubricant dispensing system to supply a lubricant from an internal reservoir disposed with in the housing to the polishing media near the end face of the ferrule of the optical connector.

12. The polishing apparatus of claim 10, wherein the connector is held in the connector mount at a predetermined angle, the predetermined angle providing for one of a flat polish that is perpendicular to the longitudinal direction of the fiber and an angled polish.

13. A method of polishing an optical fiber connector comprising:

providing an optical fiber having a stripped terminal end;

inserting the fiber through a connector body and a ferrule,

setting a protrusion of the fiber tip from an end face of the ferrule;

securing the optical fiber in the optical connector;

mounting the optical fiber connector in a connector mount portion of a polishing apparatus, the polishing apparatus including a housing having an upper portion and a base portion, a drive assembly to control orbital movement of the optical connector and linear movement of a polishing media through the polishing device; and a lubricant dispensing system;

dispensing a lubricant using the lubricant dispensing system to supply the lubricant from an internal reservoir disposed with in the housing to the polishing media near the end face of the ferrule of the optical connector; and

activating the drive assembly to polish the fiber tip protruding from the end face of the ferrule.

14. The method of claim 13, further comprising cleaving an exposed end of the optical fiber prior to setting the protrusion.

15. The method of claim 13, further comprising cleaving an exposed end of the optical fiber after the optical fiber is secured in the optical connector.

16. The method of claim 13, wherein the dispensing the lubricant comprises the step of depressing an external flexible bulb to move the lubricant from the reservoir.

17. The method of claim 13, wherein the activating the drive assembly includes pulling a string to activate the drive assembly