Alignment sleeves for interconnecting optical ferrules of dissimilar size, and methods for making same

Abstract

An alignment sleeve in accordance with the present invention interconnects optical ferrules of dissimilar size and axially aligns the ferrules with precision in a mating relationship so as to reduce loss in the optical signal passed from one ferrule to the other. A plurality of lands on the inner wall of the alignment sleeve contact and hold the respective ferrules in a predetermined axial relationship with respect to one another. The alignment sleeve comprises a compliant material which conforms to slight variances in the diameters of the ferrules received by the alignment sleeve. The alignment sleeve advantageously provides for the interconnection of ferrules of dissimilar size with precise alignment of their respective cores, which reduces the connection loss of the two ferrules. The alignment sleeve can be mass produced using injection molding techniques. The mold utilized in the injection molding process includes a precision core pin that can be manufactured using a precision grinder or lathe. The accuracy of the core pin may be fine tuned by plating thin layers of metal over portions of the core pin as may be desired to achieve precise sizing in the alignment sleeve. An alignment sleeve fabricated using a precision core pin formed in accordance with the present invention can be inexpensively manufactured with a high degree of precision.