The present invention relates to a fibre optic cable connector for use above or below ground.

Such connectors used in the laying of fibre optic cables. The cables are used, for example, to provide a fibre optic cable connection from a junction box to a building such as an office or residence in order to provide a connection for internet data.

The fibre optic cables are provided in bundles of individual fibres which can be up to several kilometres long. The fibre bundles/cables are fed through tubes (often referred to as ducts/microducts/conduits) which are typically 50 metres long, but can be as long as 2000 metres. A number of tubes may therefore need to be connected together in order to support the full run of the fibre bundle.

The connectors are provided with an annular flange at a midway point along the through bore. When feeding a fibre or fibre bundle through the connector, this is done from a location 100’s of metres or even several kilometres away. If the fibre becomes snagged, this can create a significant problem as the cable and connector may need to be dug up to identify the problem.

A typical prior art arrangement is depicted in Figs. 4A and 4B. A central annular stop S has radiused corners in order to avoid any abrupt transitions which might provide stressed concentrations which promote propagation. However, as can be seen in Fig. 4A, the radiused corner at the radially outermost part of the stop S means that the end face of the tube T at either end cannot fully seat on the end face of the stop S. As a result a gap G is created between the stop S and the tube T in which the fibre F can snag as shown in Fig. 4A. The situation in Fig. 4A assumes that the end of the tube T has been cut fully square. However, as shown in the left hand side of Fig. 4B, the situation is even worse when the tube T has been cut at an angle. In this case, the leading edge of the tube T (shown at the top of Fig. 4B) engages with the radiused corned and the tube T stops at this point. As can be seen at the bottom Fig. 4B, this creates an even bigger gap G’ on the opposite side of the connector thereby creating an even bigger snagging hazard.

The present invention is directed to solving the problem of snagging. According to the present invention, there is provided a fibre optic cable connector according to claim 1 .

By providing the undercut flange, the present invention ensures that the radially innermost edge of the tube engages with the annular flange before the radially outermost edge engages. This significantly reduces or eliminates the gap between the tube and the annular flange. In the case of a tube end which has been cut square, the presence of the undercut will eliminate the gap on both sides of the tube. In the case of a tube end which has not been cut square, the presence of the undercut will eliminate the gap on one side of the tube (unless the tube has been cut at a very oblique angle) and, on the opposite side of the tube, the gap is significantly reduced as the leading edge which has landed on the annular flange has travelled further into the connector than it would in the prior art.

Thus, by making a simple modification to the shape of the connector, the snagging problem is significantly reduced or eliminated.

In order to reduce any stress concentrations, the interface with the annular flange and the connector body is preferably radiused to provide a curved transition. Similarly, the innermost corners of the annular flange are preferably radiused to provide a curved transition.

In the prior art, the inner diameter of the flange is set to be the same as or bigger than the inner diameter of the tube being inserted into the connector. In the present case, preferably the inner diameter of the flange is smaller than the inner diameter of the tube, in use, inserted into the connector. This aspect of the invention extends to a tube cable connector in combination with a tube inserted into the connector, the inner diameter of the flange being smaller than the inner diameter of the tube.

This is a counterintuitive step as this deliberately is a decrease in the minimum inner diameter through the connector. However, making the diameter of flange slightly smaller than the inner diameter of the tube in combination with the requirement for the innermost corners of the annular flange to be radiused, means that although the annular flange protrudes slightly beyond the inner diameter of the tube, this protrusion is a curved transition such that any fibre which abuts against one of the inner most corners of the annular flange simply guided through the opening in the flange. If, as set out above, a small gap does arise between the flange and the end of the tube, the radiused corners guide the fibre away from the tube edge. It is far better for the fibre to encounter the radiused corner of the annular flange, than an abrupt and exposed edge on the end of a tube.

Another problem which arises in connectors of this type is caused by the fact that the tubes are generally supplied wound on a coil. This tends to flatten the tube such that it is deformed from a truly circular shape into an oval shape. When the tube is inserted into a connector in this oval configuration and abuts against the annular flange, its internal diameter will be larger in one direction and shorter in a transverse direction. In the direction where it is largest, this will expose the annular flange in these regions thereby providing a snagging hazard.

Preferably, therefore, a plurality of axial splines are provided on the wall of the through bore in the vicinity of the annular flange to deflect the outer wall of the tube as it approaches the flange. The splines will engage with any part of the tube which has an enlarged radius and exert radially inward force in order to push these portions radially inwardly by creating a more rounded shape at the end of the tube meets the annular flange. The requirement for axially extended splines does not mean that the splines have to extend in purely axially direction. Instead, it is sufficient that they extend a reasonably axial extent such that they will exert the inward force on the tube as it approaches the annular flange.

The splines may have a constant thickness. However, preferably, the thickness of the splines increases towards the annular flange. This allows the thinner parts of the splines away from the annular flange effectively provide a tapered entry way into the splined section, while increased spline thickness provides an increased compression force the closer the tube gets to the annular flange. The presence of the splines allows a

compressive force to be provided to the non-circular regions of the tube. However, there is still space between adjacent splines for the deformed tubed material to be pushed into so that the tube does not become stuck within the connector.

This idea forms a second aspect of the present invention which can be defined in the broadest sense as a fibre optic cable connector according to claim 10. Preferably, the body comprises an outer sleeve and an inner sleeve, the inner sleeve being configure to receive the distal end of a respective tube; the outer wall of the inner sleeve being generally spaced from an inner wall of the outer sleeve to define an air gap, the inner sleeve being supported on the outer sleeve by a discrete web of material which supports the inner sleeve and maintains the gap between the inner and outer sleeve. With this arrangement, rather than providing a number of external ribs as in a conventional connector, the impact protection of the present invention may provide by an inner sleeve which is spaced from an outer sleeve to define a gap. Preferably there is more than one web. The webs are preferably in the same radial plane. The webs are preferably axially offset from the annular flange so as not to impair visibility into that region.

With this arrangement the need for the ribs of the prior art can be significantly reduced. Preferably, this eliminates the need for ribs all together so that preferably, the outer face of the connector bodies is devoid of ribs. This removes any stress concentrators at the outer surface of the connector as well as removing any potential dirt traps.

An example of a fibre optic cable connector in accordance with the present invention will now be described with reference to the accompanying drawings in which:

Figs. 1 A-1 C are cut-away perspective views of the connector showing the progressive insertion of a tube;

Fig. 2A is a cross-sectional view of the connector body in a plane perpendicular to the main access of the connector body through line A-A in Fig. 2B;

Fig. 2B is a cross-sectional view of the connector body in plane through the main axis of the body through line B-B in Fig. 2A;

Fig. 2C is a view in the same plane as Fig 2A showing a second example of a connector;

Fig. 2D is a view in the same plane as Fig. 2B showing the second example;

Fig. 3 is a cross-section in the plane of Fig. 2B of the connector with tubes connected and a fibre bundle passing through; Fig. 3A shows the central portion of Fig. 3 in greater detail;

Fig. 3B shows a view similar to Fig. 3A, with a different configuration of tubing and without the fibre passing through;

Figs. 4A and 4B correspond to Figs. 3A and 3B illustrating a prior art arrangement;

Fig. 5 is an exploded perspective view of the connector from one end of the connector body;

Fig. 6A is the equivalent to Fig. 5 in non-exploded form, showing the cartridge and collet in a first angular configuration;

Fig. 6B is a cross-section through a plane in Fig. 6A through the locking tabs;

Figs. 7A and 7B are views corresponding to Figs. 6A and 6B respectively showing the cartridge and collet in a second angular configuration; and

Figs. 8A and 8B corresponds to Figs. 7A and 7B but show the tube in situ.

The connector comprises a connector body 1 having a generally hollow cylindrical configuration centred on a main axis X. A connector 2 (described in greater detail below) is provided at either end to receive and grip a tube T at each end which is sealed by an O ring 3.

The body 1 is moulded from a non-opaque plastic. The plastic must be such that it is clear enough that a visual inspection externally of the connector allows an operator to determine whether a fibre cable or fibre bundle F is present in the centre of the connector. Ideally, the body should be as close to transparent as possible. Flowever, practical considerations mean that the body will not be truly transparent. Instead, the body is likely to translucent to a sufficient extent that the fibre is visible. Suitable materials are polycarbonate, polystyrene, polyester, acrylic and nylon. The body 1 is formed in a moulding process and can optionally be polished to improve the clarity of the body. As can be seen in the various figures, the outer profile of the body is a smooth configuration which is devoid of external ribs thereby eliminating any stress concentrations and orifices for the accumulation of dirt. The body 1 is made up of an outer sleeve 5 and an inner sleeve 6 which are connected by at least one web 7 as described below.

The outer sleeve 5 has an axial bore 8 which is opened at the distal end 8 and which has a first step 10 and second step 1 1 which receive the connector 2 as described below.

The inner sleeve 6 is retained by the web 7 so as to form a gap 12 of generally uniform thickness as best seen in Fig. 2A.

As will be appreciated from Figs. 2A and 2B, the web 7 extends across only a very small part of the inner sleeve 6 so that the gap 12 is present for most of the length and circumference of the inner sleeve 6.

Any impact on the outer sleeve 5 which occurs during the installation of the tubing, or when the tubing is dug up for maintenance can cause deformation of the outer sleeve 5.

By providing the gap 12, the effect of any external impact on the outer sleeve 5 is isolated, to a significant extent, from the inner sleeve 6, and hence is largely prevented from causing any change to the diameter of the inner bore 14 of the inner sleeve 6. Initial tests show that this design is effective in resisting external impact. Further, this can be achieved in a manner which does not require the addition of ribs and does not require an increase in the outer diameter of the connector.

Use of the very small size of the web 7 means that the chance of an impact being directly transmitted from the outer sleeve 5 to the inner sleeve 6 via the web 7 is greatly reduced. Even if this were to occur (i.e. an impact were to be applied in the vertical downward direction in Fig. 2A at the centre point connector in Fig. 2B), the inner sleeve 6 can still deflect by an amount equivalent to the width of the gap 12 before any stresses occur on the inner sleeve which would have an adverse effect on the internal bore 14 of the inner sleeve 6.

In order to mould the body 1 all of the plastic required for the inner sleeve 6 is required to pass through the webs 7, 15. This represents a reasonably significant amount of plastic which flows into a relatively complex and narrow flow path. In order to alleviate this, we are contemplating providing one or more additional webs 13 depicted schematically in Fig. 2A these are angularly offset with respect to the web 7 and may also be axially offset to ensure that there is no point at which the inner sleeve 6 is supported on diametrically opposed sides. The additional web 13 provide further flow paths for the plastic into the inner sleeve during the moulding process. Multiple webs can be made weaker than a single web such that whichever web is closest to the impact will preferentially fracture under an applied load leaving the remaining ribs to support the inner sleeve 6.

Instead of extending in a radial sense as shown in Fig. 2A, the or each web 15 may extend tangentially as shown in Fig. 2C, or in any other direction across the gap 12. As shown in Fig. 2D, the webs 15 are axially offset from an annular flange 20 so that they do not impair the visibility into this region. The outer sleeve 5, inner sleeve 6, web(s) 7 and annular flange are preferably all moulded as a single component as illustrated.

The manner in which the connector is configured in order to avoid snagging of the fibre F will now be described with reference to Figs. 3, 3A and 3B with Figs. 4A and 4B being used to provide a comparison with the prior art.

Fig. 3 shows the connector body 1 with a tube T fixed and sealed in either end. Once connected in this way, the fibre F is blown from one end through the tube T, across the interface between the tubes and into the adjacent tube.

The tubes T abut against the annular flange 20 at a midpoint of the inner sleeve 6. The connectors 2 and O-rings 3 broadly have the same inner diameter as the inner diameter of the inner sleeve 6 so that, when the tube T is pushed into the body 1 , it is guided into the inner sleeve 6. The end of the tube T then abuts the annular flange 20. As best seen in Figs. 3A and 3B, each end of the annular flange 20 is provided undercut portion 21 such that the thickness of the annular flange 20 in the axial direction increases towards the axis X.

As a result of this, the innermost corner 22 of the tube T is the first part of the tube T to abut the annular flange 20. This means that there is no gap between the inner face 23 of the tube T and the annual flange 20. The undercut portion 21 is radiused as shown in Figs. 3A and 3B. Similarly, the radially innermost corners 24 of the annular flange are radiused to present a smooth surface to the fibre.

In comparison with the prior art arrangement shown in Fig. 4A, the elimination of the gap G between the end of the tube T and the annular flange 20 means that there is no exposed abrupt edge of the tube T for the fibre F to snag on.

Fig. 3B depicts the situation where the left hand tube has been cut at an angle which is slightly oblique to a plane perpendicular to the axis X. As a result of this, the uppermost edge 25 of the tube T enters into the undercut region 21 and seats on the annular flange 20.

By comparison with Fig. 4B it can be seen that the gap between the tube T and the annular flange 20 is eliminated in the top half of the figure and the gap at the bottom is significantly reduced as compared to Fig. 4B.

As will to be apparent from Figs. 3A and 3B, the radially inward extent of the annular flange 20 is greater than the inner diameter of the tube T. As a result of this, the annular flange 20 protrudes slightly inwardly beyond the inner face 23 of the tube T. From a comparison of Figs. 3B and 4B, if it is assumed that the fibre F is fed from right to left, and in the vicinity of the connector 1 the tip of the fibre is travelling along the lower part of the inner face 23 in Figs. 3A and 4B, in the Fig. 3B, this will initially encounter the corner of the annular flange 20 which projects slightly beyond the inner surface 23 of the tube T. Flowever, the fibre F can easily ride over this curved corner and, in doing so, this deflection should push the tip of the fibre above the exposed edge 28 of the tube T. By contrast, in Fig. 4B, annular projection S does not protrude beyond the inner surface 23 of the tube so there is nothing to begin to deflect the fibre F back towards the centre of the bore. Further, the gap G’ in Fig. 4B is significantly larger than the corresponding gap in Fig. 3B. This, not only is fibre not deflected away from this gap, the presence of the large gap affords a significantly greater opportunity for fibre to enter the gap and become snagged on the edge 28 of the tube T.

A further feature which prevents snagging of the tube is the splined arrangement listed as best illustrated in Figs. 1 and 2. As can be seen from these figures, six axially extending splines 30 are equally spaced around the circumference of the inner sleeve 6. These are shown having a constant cross- section in a plane perpendicular to the axis. However, they may have a thickness increases towards the annular flange 20.

As shown in Figs. 1 A and 1 B, a tube T has been fed from a coil and has taken on a flattened oval shape. As this enters the inner sleeve 6 the tube T engages with the enlarged portions of the tube T and tend to push this back to a more circular shape as shown in Fig. 1 C.

Any number of splines may be used. However six has been found to be a reasonable number. This allows engagement with a flattened tube which is inserted in any orientation. A smaller number of flanges risks the possibility that the enlarged part of the tube enters between adjacent splines. On the other hand, adding more splines increases the insertion resistance for the tube T into the connector 1 .

The splines 30 are dimensioned such that where the splines are present is slightly smaller than the outer diameter of the tube. The splines 30 will therefore bite into the material of the tube T in these regions. This ensures a secure and robust fit of the tube T and also provides the maximum opportunity for the splines to reduce the eccentricity of the tube.

The arrangement of the annular flange 20 and the splines 30 has been described in the context of the arrangement with the outer sleeve 5 and inner sleeve 6 supported by a web 7. Both the annular flange 20 and the splines 30 could, however, be employed in a connector with a more conventional construction which does not have the inner sleeve 6. Instead, the through bore and inner flange are formed directly in the main body. With such an arrangement, reinforcing ribs would be provided in order to give enhanced impact resistance.

There is, however, a synergy between the enhanced impact resistance provided by the inner sleeve 6 and the web 7 and the arrangement of the annular flange 20. The impact test carried out these connectors requires the connector to be subjected to an impact and that this impact does not cause a reduction of more than 15% of the inner diameter of the tube. As set out above, the annular flange 20 already protrudes a small amount into this area. This provides an anti-snagging benefit. However, it does mean that a smaller inward deformation of the connector in the vicinity of the annular flange 20 would fail the impact test as we have already pre-engineered the annular flange to go some way towards encroaching on the 15% region beyond which it will fail the test. However, because of the enhanced ability of the sleeve 6/web 7 arrangement to resist impact, we can afford to make the reduction in the inner diameter in order to improve the anti-snagging properties whilst still maintaining sufficient impact resistance to reliably meet the test requirements.

The connectors 2 (one at each end of the body 1 ) will now be described in greater detail with reference to Figs. 5 to 8.

The connectors 2 are formed of two components, namely a cartridge 40 and a collet 41.

The cartridge 40 has a generally annular configuration. The outer surface is provided with a plurality of flexible metal teeth 42. The cartridge 40 is inserted into an end of the body 1 until it seats against the second step 1 1. The teeth 42 grip the wall of the body 1 to ensure that the cartridge 40 is permanent retained in the body 1 . At the end of the cartridge 40 adjacent to the second step 1 1 , there is a tapered cam surface 43 which cooperates with the collet as described below. At the opposite end, the end face of the cartridge 40 is provided with a pair of ramped surfaces 44. Although two such surfaces are shown, there may be a single surface or there may be more than two. Each ramp surface has a low point 45 corresponding to an unlocked configuration and a high point 46 corresponding to a locked configuration within an inclined face 47 in between. A bump 48 is provided at the interface between the high point 46 and the inclined face 47. A similar bump may be provided interface between the incline face 47 and the low point 45. The low point 45 terminates at the first end stop 49 and the high point 46 terminates at a second end stop 50.

Most of the features of the collet 41 are conventional. It has a collet ring 52 from which a plurality of flexible arms 53 extend. Each arm has a head 54 at its distal end as is provided with an inwardly projected metal tooth 55.

With a tube T inserted for example as shown in Fig. 8B, any movement tending to pull the tube T out of the connector causes the teeth 55 to grip into the tube, this pulls the heads 54 towards the tapered cam surface 43 on the cartridge 40 deflecting the arms 53 inwardly to provide a progressively increasing gripping force on the tube T. This serves to hold the tube T securely in place. This is the conventional manner in which a collet operates.

The adaptation provided by the present invention is the presence of a pair of cam followers

56 extending from the collet ring 52 towards the ramped surface 44 on the cartridge 40. Although two followers 56 are shown, in practice there are as many followers 56 as there are ramped surfaces 44. Alternatively, the cam arrangement may be inverted such that the ramped surface(s) is/are on the collet and the follower(s) is/are on the cartridge

The collet ring 52 is also provided with a pair of tabs 57 which extend from the collet ring 52 the opposite direction to the followers 56. As shown in the drawings, the position of the tabs

57 corresponds to a number and position of the followers 56. However, this may not be the case. The components can be offset from one another and there need not be same number of both.

The operation of the collet will now be described with reference to Figs. 6 to 8. The position shown in Figs. 6A and 6B is an unlocked position. In this position, the collet 41 has been rotated such that cam followers 56 abut the first end stops 49 such that the cam followers are at the low point 45. As will be apparent from Fig. 6B (particularly when compared with Fig. 7B) in this position, the collet 41 has a relatively large degree of axial freedom as it can move from the position in which the heads 54 engage with the tapered cam surface 43 all the way to the left (with reference to Fig. 6B) in the position shown in that figure. If held in that position by a user, the tube T can be withdrawn because the heads 54 are kept away from the tapered inclined surface 43 such that the collet cannot grip the tube. The collet 41 is then rotated in the direction of arrow 60 into the locked position shown in Fig. 7A. In doing so, the followers 56 moves up the inclined faces 57, over the bumps 48, providing a tactile feel to the user that a position has been reached, and onto the high point 46.

As will be appreciated from a comparison of Fig. 6B and Fig. 7B, in the locked position shown in Fig.7B, the collet has nothing like the same degree of freedom as in Fig. 6B so that it cannot be moved and held into an unlocked position where the teeth 55 disengage with the tube T. This is more apparent from Figs. 8A and 8B which show the collet in the same locked position as in Figs. 7A and 7B but with the tube in place. Here it can be seen how the presence of the tube pushes the heads 54 back onto the tapered cam surface 43. The only way to remove the tube T in this locked configuration is for the user to grasp the tabs 57, rotate the collet 41 in the direction of arrow 61 in Figs. 6A to the unlocked position, and manually hold the collet in the position shown in Fig 6B while pulling the tube out of the body 1.

The tube T will usually be inserted with the collet 41 in the unlocked position shown in Figs. 6A and 6B as this allows for more scope for the arms 53 to be deflected upon insertion of the tube. Flowever, as can be seen in Fig. 7B, even in the locked position, there is a small clearance between the head 54 and the tapered cam surface 43. Thus, it is possible to insert the tube T with the collet in the locked position. This provides a simple assembly process as the user needs only to be told to insert the tube into the collet. They do not need to concern themselves with the locking operation.

As can be best seen from Figs. 1 A to C and Fig. 3, the collet ring 52 is axially set back inside the body 1 . Flowever, the tabs 57 extend beyond the end of the body 1. In this position, the collet 41 is protected from external impacts by the body 1 . Further, because it is recessed within body 1 , it is, to some extent, shielded from the soil in which the cables are buried. With this connector, the only points where dirt can potentially enter internal workings of the connector are between the collet ring 52 and the tube T and between the collet ring 52 and the body 1 . Flowever, these are interfaces where tight tolerances can be applied. Any dirt entering here cannot impair the visibility of the fibre F within the body 1. Further, because of the rotary action required to unlock the collet, even if some dirt does enter into these gaps, this is unlikely to jam the collet 41 in place as a rotary motion can readily generate sufficient torque to overcome any such sticking.