MANUFACTURING AND USING FERRULE-LESS MULTI-FIBER CONNECTORS
A connection system includes an optical connector assembly; and an optical plug. The connector assembly includes a stack of gel-groove assemblies and a spring assembly mounted within a housing. Each of the gel-groove assemblies includes a first gel block at a first axial end, a second gel block at a second axial end, and a fiber mating region between the first and second gel blocks. The optical plug including sub-modules over-molded over arrays (e.g., ribbons) of the optical fibers. Each sub-module defines notches for receiving latches of the spring assembly when the optical plug is coupled to the first axial end of the optical adapter. Bare optical fibers extend from the plug, pass through the first axial gel block, and enter the fiber mating region when the plug is coupled to the adapter.
1 . A connectorized optical cable comprising:
(a) a cable including a plurality of optical fibers;
(b) a sub-module formed around an array of at least some of the optical fibers, the sub-module defining notches at longitudinal sides of the sub-module, wherein front sections of the optical fibers of the ribbon extend forwardly of the sub-module, the front sections not being held by optical ferrules;
(c) an inner housing that receives and positions the sub-module; and
(d) an outer housing that surrounds the inner housing and sub-module, the outer housing having a rear end that secures to the cable and an open front end through which tips of the optical fibers are accessible.