Patent Number: 7,086,847

Title: Guide block assembly for molding multi-fiber connectors

Abstract: A guide block assembly for aligning and retaining fiber bore forming pins and guide pin bore forming pins in precise relation to each other during the molding of a multi-fiber ferrule includes a unitary member defining at least one fiber bore and at least one guide pin bore. Each fiber bore, and optionally each guide pin bore, is formed by creating a starter hole using a first electric discharge machining (EDM) wire and enlarging the starter hole using a second EDM wire. Each fiber bore has a length to diameter ratio of between approximately 3:1 to 10:1, more preferably between approximately 4:1 to 8:1, and most preferably approximately 6:1. The guide block assembly may further include a cavity behind the fiber bore and a front face that forms a non-rectilinear surface on the face of the ferrule. The unitary block assembly contains fewer parts and is less expensive to manufacture.

Inventors: Dean, Jr.; David L. (Hickory, NC), Felkenes; Nick A. (West Carrollton, OH), Malanowski; Alan J. (Newton, NC)

Assignee: Corning Cable Systems LLC

International Classification: B29C 33/76 (20060101)

Expiration Date: 8/08/02018