U.S. patent application number 16/574647 was filed with the patent office on 2020-04-30 for methods for processing ferrules and/or optical fibers.
This patent application is currently assigned to COMMSCOPE TECHNOLOGIES LLC. The applicant listed for this patent is COMMSCOPE TECHNOLOGIES LLC COMMSCOPE ASIA HOLDINGS B.V.. Invention is credited to Dwight Andrew BRETZ, Tom DE BOER, Dirk Alexander DE GAST, Robert Charles FLAIG, Michael Lawrence GURRERI, Michael Aaron KADAR-KALLEN, Randall Bobby PAUL, Paul SCHNEIDER, Joshua Lee WEBB.
Application Number | 20200132943 16/574647 |
Document ID | / |
Family ID | 58717884 |
Filed Date | 2020-04-30 |
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United States Patent
Application |
20200132943 |
Kind Code |
A1 |
FLAIG; Robert Charles ; et
al. |
April 30, 2020 |
METHODS FOR PROCESSING FERRULES AND/OR OPTICAL FIBERS
Abstract
The present disclosure relates generally to methods for
processing ferrules of fiber optic connectors such that the amount
of polishing that is required is eliminated or at least reduced. In
one example, an energy source is used to remove excess adhesive
from the end face of the fiber and likely from an end face of the
ferrule.
Inventors: |
FLAIG; Robert Charles;
(Lancaster, PA) ; GURRERI; Michael Lawrence;
(York, PA) ; WEBB; Joshua Lee; (Stewartstown,
PA) ; KADAR-KALLEN; Michael Aaron; (Harrisburg,
PA) ; PAUL; Randall Bobby; (Elizabethville, PA)
; BRETZ; Dwight Andrew; (Hummelstown, PA) ;
SCHNEIDER; Paul; (Gemonde, NL) ; DE BOER; Tom;
(Utrecht, NL) ; DE GAST; Dirk Alexander;
(Geldermalsen, NL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
COMMSCOPE TECHNOLOGIES LLC
COMMSCOPE ASIA HOLDINGS B.V. |
Hickory
Bussum |
NC |
US
NL |
|
|
Assignee: |
COMMSCOPE TECHNOLOGIES LLC
Hickory
NC
COMMSCOPE ASIA HOLDINGS B.V.
Bussum
|
Family ID: |
58717884 |
Appl. No.: |
16/574647 |
Filed: |
September 18, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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15777620 |
May 18, 2018 |
10451815 |
|
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PCT/US2016/062857 |
Nov 18, 2016 |
|
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16574647 |
|
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62257041 |
Nov 18, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G02B 6/3861 20130101;
H01J 37/32009 20130101; G02B 6/381 20130101; G02B 6/3853 20130101;
G02B 6/3863 20130101; B23K 26/402 20130101 |
International
Class: |
G02B 6/38 20060101
G02B006/38; B23K 26/402 20060101 B23K026/402; H01J 37/32 20060101
H01J037/32 |
Claims
1-40. (canceled)
41. A method for processing a ferrule assembly including a ferrule
supporting an optical fiber, the method comprising: (a)
mechanically polishing a distal end of the optical fiber and a
distal end face of the ferrule; and (b) processing the distal end
of the optical fiber to round and shape the distal end face of the
optical fiber using a non-contact energy source after the
mechanical polishing.
42. The method of claim 41, wherein: (a) the step of processing the
distal end face of the optical fiber includes a laser ablation
process.
43. The method of claim 41, wherein: (a) the non-contact energy
source is used to remove imperfections from the distal end of the
optical fiber.
44. The method of claim 41, wherein: (a) the non-contact energy
source is used to clean the distal end of the optical fiber.
45. A method for processing a multi-fiber ferrule supporting a
plurality of optical fibers, the optical fibers having a distal
protrusion length relative to a distal end face of the multi-fiber
ferrule, the method comprising: (a) establishing the fiber
protrusion length by laser ablating the distal end face of the
multi-fiber ferrule without ablating the optical fibers; and (b)
processing distal ends of the optical fibers with a plasma
discharge to round and shape the distal ends of the optical fibers
after the fiber protrusion length has been established.
46. The method of claim 45, wherein: (a) the optical fibers include
GRIN fibers fused to ends of the optical fibers secured within the
ferrule.
47. The method of claim 45, wherein: (a) the plasma discharge is
used to remove imperfections from the distal ends of the optical
fibers.
48. The method of claim 45, wherein: (a) the plasma discharge is
used to clean the distal ends of the optical fibers.
49. The method of claim 41, wherein: (a) the optical fiber includes
a GRIN fiber fused to an end of the optical fiber secured within
the ferrule.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a Continuation of U.S. patent
application Ser. No. 15/777,620, filed on May 18, 2018, which is a
National Stage Application of PCT/US2016/062857, filed on Nov. 18,
2016, which claims the benefit of U.S. Patent Application Ser. No.
62/257,041, filed on Nov. 18, 2015 the disclosures of which are
incorporated herein by reference in their entireties. To the extent
appropriate, a claim of priority is made to each of the above
disclosed applications.
TECHNICAL FIELD
[0002] The present disclosure relates generally to methods for
processing components of fiber optic connectors. More particularly,
the present disclosure relates to methods for processing ferrules
and corresponding optical fibers used in fiber optic
connectors.
BACKGROUND
[0003] Fiber optic communication systems are becoming prevalent in
part because service providers want to deliver high band width
communication capabilities (e.g., data and voice) to customers.
Fiber optic communication systems employ a network of fiber optic
cables to transmit large volumes of data and voice signals over
relatively long distances. Fiber optic connectors are an important
part of most fiber optic communication systems. Fiber optic
connectors allow optical fibers to be quickly optically connected
without requiring a splice. Fiber optic connectors can include
single fiber connectors and multi-fiber connectors.
[0004] A typical fiber optic connector includes a ferrule assembly
supported at a distal end of a connector housing. A spring is used
to bias the ferrule assembly in a distal direction relative to the
connector housing. The ferrule functions to support an end portion
of at least one optical fiber (in the case of a multi-fiber
ferrule, the ends of multiple fibers are supported). The ferrule
has a distal end face at which a polished end of the optical fiber
is located. When two fiber optic connectors are interconnected, the
distal end faces of the ferrules abut one another and the ferrules
are forced proximally relative to their respective connector
housings against the bias of their respective springs. With the
fiber optic connectors connected, their respective optical fibers
are coaxially aligned such that the end faces of the optical fibers
directly oppose one another. In this way, an optical signal can be
transmitted from optical fiber to optical fiber through the aligned
end faces of the optical fibers. U.S. Pat. Nos. 5,883,995 and
6,142,676, which are hereby incorporated by reference in their
entireties, disclose a ferrule-less fiber optic connector having an
optical fiber having a ferrule-less end portion that is accessible
at a front end of a connector body of the fiber optic connector.
U.S. Pat. No. 6,957,920, which is hereby incorporated by reference
in its entirety, discloses a multi-fiber ferrule having protruding
optical fibers.
[0005] The manufacturing process of optical connectors typically
consists of 8-15 steps generalized as: Fiber and Cable Preparation,
Epoxy and Cure, Cleave, Epoxy Removal, Polish, and others.
Arguably, the most performance-critical step in the manufacture of
optical connectors lies in the geometry formation process (Cleaving
through Polish). These steps greatly influence the fiber's physical
contact between adjoining optical connectors and ultimately
determine a connector's ability to transmit (optical signal power
coupling loss) and reflect the transmission signal.
[0006] Polishing is a multi-step process where the end-face of the
ferrule and the fiber are gradually worked and reshaped using
different grade polishing materials until the desired radius,
angle, flatness and surface quality (roughness) is achieved. The
number of polishing steps is connector dependent, ranging from 3 or
4 steps for simplex connectors, to 5 or 6 steps in multi-fiber
connectors. Generally, polishing is time consuming, labor intensive
and messy. In an effort to reduce manufacturing cycle time, reduce
manufacturing complexity, and, ultimately remove manufacturing
costs, it is desirable to reduce the number of steps required for
polishing a connector.
SUMMARY
[0007] One aspect of the present disclosure relates to ferrule and
fiber processing methods utilized to reduce or eliminate dependence
upon abrasive mechanical polishing techniques. In certain examples,
processing techniques using non-contact energy sources (e.g.,
plasma discharges, lasers, torches, infrared heating, etc.) can be
used to remove undesired material (residues such as adhesive (e.g.,
epoxy), dust, electrostatic particles, or other contaminants) from
the end face of a ferrule and/or the end face of an optical fiber
supported by the ferrule. In certain examples, the processing
techniques can be implemented after the optical fiber has been
axially fixed within the ferrule. In certain examples, the
processing to remove undesired materials can eliminate the need for
subsequent polishing steps. In other examples, the processing to
remove undesired materials can be used in combination with a
subsequent mechanical polishing step for finishing or shaping the
optical fiber end. Mechanical polishing can also be used to adjust
a fiber protrusion length relative to the ferrule. However, by
using non-contact processing steps, subsequent mechanical polishing
steps can be less substantial as compared to if mechanical
polishing were also used to remove the undesired materials.
[0008] Processing techniques as disclosed herein can be used with
respect to optical fibers having end faces that are forwardly
offset, flush or recessed relative to the end faces of their
corresponding ferrules. Aspects of the present disclosure are
applicable to the processing of both single fiber and multi-fiber
ferrules. After an optical fiber has been secured relative to a
corresponding ferrule, non-contact processing techniques of the
type disclosed herein can be used to remove undesired material from
the optical fiber and the ferrule and/or can be used to modify the
end face of the optical fiber supported by the ferrule after the
optical fibers have been secured in their respective ferrules. For
example, the processing techniques can be used to shape the optical
fiber ends (e.g., to provide desired fiber tip radii or other
shaping) or to re-flow the optical fiber ends to remove scratches
or other imperfections that may negatively affect optical signal
transmission.
[0009] In certain examples of the present disclosure, the optical
fiber can be cleaved and processed prior to insertion in its
corresponding ferrule. For example, the optical fiber can be
mechanically or laser cleaved prior to insertion in its
corresponding ferrule. Also, the optical fiber can be pre-processed
(e.g., processed by techniques such as mechanical polishing or the
application of a non-contact energy source) to shape the optical
fiber (e.g., provide a desired fiber tip radius) and/or treat the
end face of the optical fiber to remove imperfections.
[0010] In one aspect, the present disclosure relates to a method
for processing an optical fiber and for securing the optical fiber
to a ferrule. The ferrule includes a ferrule body having a distal
end and a proximal end. The ferrule body also defines a fiber
opening that extends axially through the ferrule body from the
proximal end to the distal end. The method can include the steps
of: 1) processing a distal end face of the optical fiber so as to
form a pre-processed end face of the optical fiber; 2) applying
adhesive within the fiber opening of the ferrule body; 3) inserting
the optical fiber with the pre-processed end face through the
adhesive filled opening of the ferrule body and positioning the
optical fiber within the fiber opening such that the pre-processed
end face of the optical fiber is located at a pre-determined axial
position relative to the distal end of the ferrule body; 4) curing
the adhesive to fix the optical fiber within the fiber opening such
that the pre-processed end face of the optical fiber is fixed at
the pre-determined axial position relative to the distal end of the
ferrule body; and 5) removing excess adhesive from the
pre-processed end face of the optical fiber using a non-contact
energy source.
[0011] Another aspect of the present disclosure relates to a method
that can include the steps of: 1) pre-processing an end face of the
optical fiber; 2) inserting the pre-processed fiber through a
ferrule; 3) retracting the pre-processed fiber back into the
ferrule; 4) wiping excess adhesive from an end face of the
pre-processed fiber; 5) setting an exact fiber position within the
ferrule; 6) cure the adhesive; and 7) remove excess adhesive from
the end face of the pre-processed fiber with a non-contact energy
source.
[0012] A further aspect of the present disclosure relates to a
method for processing a ferrule supporting a beam expansion
structure (e.g., a lens such as a GRIN lens). In certain examples,
an optical waveguide including a lens (e.g., a GRIN lens fused to
an optical fiber) is positioned within a ferrule. In certain
examples, the lens can be mounted (e.g., secured, retained, bonded,
axially fixed, etc.) within an opening defined by the ferrule. In
certain examples, the lens can be axially fixed relative to the
ferrule (e.g., with an adhesive such as epoxy) with an end face of
the lens set at a desired axial position relative to an end face of
the ferrule. In certain examples, the end face of the lens can be
forwardly offset, flush or recessed relative to the end face of the
ferrule. In certain examples, a non-contact energy source (e.g., a
laser, plasma discharge, or other energy source) can be used to
remove undesired material (e.g., adhesive, contaminants, dust,
etc.) from the end face of the lens after the lens has been axially
fixed relative to the ferrule.
[0013] Yet another aspect of the present disclosure relates to an
APC connector with an end face of a ferrule angled relative to a
central axis of an optical fiber. In one example, the end face is
angled about 8 degrees relative to the central axis of the optical
fiber. In the case of an APC connector, an example method includes
the steps of: 1) pre-processing an end face of an optical fiber; 2)
applying adhesive in a fiber passage defined by a ferrule; 3)
inserting the pre-processed optical fiber into the opening
containing the adhesive; 4) setting an axial position of the
optical fiber within the ferrule; 5) removing excess adhesive from
the pre-processed end face of the optical fiber using a non-contact
energy source; 6) determining a core offset of the optical fiber;
and 7) polishing the end face of the ferrule to achieve a 8 degree
angle relative to the core offset of the optical fiber.
[0014] A variety of additional aspects will be set forth in the
description that follows. The aspects relate to individual features
and to combinations of features. It is to be understood that both
the foregoing general description and the following detailed
description are exemplary and explanatory only and are not
restrictive of the broad inventive concepts upon which the
embodiments disclosed herein are based.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a front, perspective, cross-sectional view of a
ferrule assembly in accordance with the principles of the present
disclosure.
[0016] FIG. 2 is a rear, perspective view of the ferrule assembly
of FIG. 1.
[0017] FIG. 3 is a cross-sectional view taken along section line
3-3 of FIG. 1, the cross-sectional view shows a bare fiber portion
of an optical fiber of the ferrule assembly.
[0018] FIG. 4 is a cross-sectional view taken along section line
4-4 of FIG. 2, the cross-section shows a coated fiber portion of
the ferrule assembly.
[0019] FIG. 5 is a cross-sectional view showing an alternative
configuration for the coated fiber portion of FIG. 4.
[0020] FIGS. 6-10, 10A, 11 and 12 illustrate a sequence of steps
for securing the optical fiber within a ferrule in accordance with
the principles of the present disclosure.
[0021] FIG. 13 is a schematic, longitudinal cross-sectional view
showing a mode field for the optical fiber spliced to a GRIN lens
fiber within a ferrule in accordance with the principles of the
present disclosure.
[0022] FIG. 14 is a schematic view of the ferrule shown in FIG. 13
mated with a reference ferrule for setting a desired recess
distance in accordance with the principles of the present
disclosure.
[0023] FIG. 15 is a flow chart illustrating a method for processing
the optical fiber including the GRIN lens as shown in FIG. 13 in
accordance with the principles of the present disclosure.
[0024] FIG. 16 is a flow chart illustrating another method for
processing a distal end face of the optical fiber and a distal end
of the ferrule along a plane angled relative to a central axis of
the optical fiber.
[0025] FIG. 17 is a flow chart illustrating a method for
establishing an end face geometry for an optical fiber and/or a
cylindrical ferrule supporting the optical fiber in accordance with
the principles of the present disclosure.
[0026] FIG. 18 is a flow chart illustrating another method for
establishing end face geometries for optical fibers and/or a
generally rectangular multi-fiber ferrule supporting the optical
fibers in accordance with the principles of the present
disclosure.
[0027] FIG. 19 is an end view of a multi-fiber ferrule in
accordance with the principles of the present disclosure.
[0028] FIG. 20 is a side view of the multi-fiber ferrule of FIG.
19.
[0029] FIG. 21 is a bottom view of the multi-fiber ferrule of FIG.
19.
DETAILED DESCRIPTION
[0030] Aspects of the present disclosure relate to the effective
use of non-contact energy source treatment techniques to simplify
operations and reduce cost associated with manufacturing an optical
component including a ferrule supporting an optical fiber.
Traditionally, the significant reliance upon mechanical polishing
operations including abrasives (e.g., abrasive flocks, abrasive
slurries, abrasive pads or discs, etc.) results in substantial cost
and complexity associated with processing optical fibers and their
corresponding ferrules. Certain aspects of the present disclosure
relate to the use of non-contact energy source treatment techniques
to replace one or more mechanical polishing steps. Certain aspects
relate to ferrule and optical fiber processing methods that do not
require any mechanical polishing steps. Other aspects relate to
ferrule and fiber processing methods that reduce the number,
complexity or abrasiveness of the mechanical polishing steps used.
Processes of the present disclosure are applicable to single fiber
ferrules and multi-fiber ferrules.
[0031] As used herein, non-contact energy source treatment
techniques relate to treatment techniques that do not require
direct mechanical contact with the contact ferrule/optical fiber
but instead involve exposing the ferule and/or optical fiber to an
energy source which brings about a desired treatment result. One
example non-contact energy source treatment technique involves
exposing the ferrule/optical fiber to a plasma such as the arc
discharge caused by electrical current breaking down and flowing
through a normally nonconductive media (e.g., air) between two
spaced-apart electrodes. In this regard, corona treatment devices
can be used to ionize air by applying a voltage between two pointed
electrodes to generate a corona discharge plasma between the
electrodes. By exposing a surface desired to be treated to the
plasma, the characteristics of the surface can be altered and/or
materials can be removed. Another example non-contact energy source
treatment technique involves exposing the ferrule and/or optical
fiber to a laser beam. An example device for generating such a
laser beam includes a carbon dioxide (CO.sub.2) laser. Further
examples of non-contact energy source treatment techniques involve
exposing the ferrule and/or optical fiber to a torch flame (e.g.,
from a gas torch), exposing the ferrule/optical fiber to infrared
heat from an infrared heat source, and exposing the ferrule/optical
fiber to certain types of electro-magnetic wave-based energy
sources.
[0032] The various methods disclosed herein can be used to
manufacture ferrule/fiber assemblies having optical fiber tips that
project distally beyond and end face of the ferrule, are flush
relative to the end face of the ferrule, or are recessed relative
to the end face of the ferrule. In the case of single fiber
ferrules, in certain examples, a final fixed tip position of the
optical fiber can be in the range of -125 microns (i.e., recessed
up to and including 125 microns) to +50 microns (i.e., protruding
up to and including 50 microns) relative to an end face of the
ferrule. In the case of multi-fiber ferrules, in certain examples,
the optical fibers can have final fixed tip positions that protrude
30 to 50 microns beyond the end face of the ferrule.
[0033] One aspect of the present disclosure relates to the use of a
non-contact energy source to remove unwanted material from the end
face of a ferrule and/or the tip of an optical fiber supported by
the ferrule. In certain examples, the ferrule can be a multi-fiber
ferrule or a single fiber ferrule. In certain examples, the
unwanted material includes residue of an adhesive (e.g., epoxy)
used to retain an optical fiber within the ferrule. In certain
examples, a non-contact energy source can be used to expedite a
cure time of the adhesive used to secure the optical fiber within
the ferrule. In certain examples, the unwanted material can include
a contaminant such as dust or debris. In certain examples, the
non-contact energy source can be used to remove material from the
face of an optical fiber that is recessed relative to the
corresponding ferrule face. This allows the material to be removed
without changing the distance the optical fiber tip is recessed
relative to the ferrule end face. In certain examples, the
non-contact energy source can be used as an electrostatic cleaner.
In certain examples, the removal of the unwanted materials (e.g.,
adhesive or contaminants) using the non-contact energy source can
be a final step in preparing the end face of the ferrule and/or the
fiber tip. In this example, after removal of the material, the
optical fiber tip has a resultant surface quality and shape that
further processing is not needed to satisfy pertinent performance
standards relating to optical signal loss (e.g., insertion loss,
return loss, etc.).
[0034] In certain examples, the removal of the unwanted materials
(e.g., adhesive or contaminants) using the non-contact energy
source can be an intermediate step in preparing the end face of the
ferrule and/or the fiber tip so as to simplify subsequent steps. In
such examples, after material has been removed using the
non-contact energy source, the end of the ferrule and/or the
optical fiber tip can be subsequently processed using mechanical
polishing techniques or further non-contact energy source
applications to further process the end of the ferrule and/or the
fiber tip. Such subsequent processing steps can be used to control
the degree of protrusion of the optical fiber (e.g., mechanical
polishing, plasma treatment or laser ablation can be used to remove
material of the ferrule to increase fiber protrusion; mechanical
polishing, plasma treatment or laser ablation can be used to remove
material from the optical fiber to decrease fiber protrusion). Such
subsequent processing steps (mechanical polishing or non-contact
energy techniques) can also be used to modify the fiber tip shape
and/or the ferrule end shape (e.g., the ferrule can be stepped, the
ferrule can be rounded, the ferrule end surface and the fiber tip
can be angled, the fiber tip can be treated to remove
imperfections, the fiber tip can be rounded to a desired tip
radius, etc.).
[0035] Another aspect of the present disclosure relates to the use
of a non-contact energy source to process the fiber tip of an
optical fiber after the optical fiber has been secured in a
ferrule. For example, the non-contact energy source can be used to
shape the fiber tip or re-flow the surface of the fiber tip after
the optical fiber has been secured to within the ferrule. Shaping
the fiber tip can include modifying the fiber tip to include at
least some curvature. In certain examples, the fiber tip and the
ferrule end are modified in shape so as to comply with industry
standards for end face geometry. In certain examples, the fiber tip
can be provided with at a least portion having a spherical shape of
a desired radius. In certain examples, re-flowing the surface of
the fiber tip can assist in reducing loss-inducing imperfections in
the surface. Shaping can be particularly effective for optical
fibers that have been set relative to their corresponding ferrules
so that the fiber tip protrudes beyond the ferrule end face, but
can also be used for flush and recessed fiber tips. Re-flowing is
equally applicable to protruding, flush and recessed fiber tips. It
will be appreciated that this type of processing can be a final
processing step that results in the fiber having a fiber tip shape
and surface quality suitable for meeting pertinent optical
performance standards relating to loss (e.g., return loss,
insertion loss, etc.). In this type of example, the non-contact
processing can follow earlier processing operations (e.g., adhesive
removal, polishing, ferrule removal/shaping, etc.). In other
examples, the non-contact processing can be followed by subsequent
processing operations (e.g., polishing, further non-contact
processing, etc.).
[0036] Another aspect of the present disclosure relates to the use
of a non-contact energy source to process the fiber tip of an
optical fiber before the optical fiber has been secured in a
ferrule. For example, the non-contact energy source can be used to
shape the fiber tip or re-flow the surface of the fiber tip before
the optical fiber has been secured to within the ferrule. Shaping
the fiber tip can include modifying the fiber tip to include at
least some curvature. In certain examples, the fiber tip can be
provided with at a least portion having a spherical shape of a
desired radius. In certain examples, re-flowing the surface of the
fiber tip can assist in reducing loss-inducing imperfections in the
surface. In certain examples, the ferrule can be pre-made with a
desired shape prior to insertion of the optical fiber within the
ferrule. For example, the ferrule can be pre-molded or
pre-processed so as to have a desired end shape, polish level,
angle, or other characteristic. With a pre-shaped ferrule and a
pre-processed optical fiber, minimal processing may be needed after
the optical fiber has been secured within the ferrule. In certain
examples, subsequent processing may include using a non-contact
energy source to remove excessive adhesive from the optical fiber
tip and the end face of the ferrule after adhesive has been used to
secure the optical fiber within the ferrule.
[0037] In certain examples, a laser is used to process an end face
of an optical fiber before or after the optical fiber is loaded
into an adhesive filled fiber passage within a ferrule.
Characteristics of the laser (focal spot intensity, interaction
time, wave length, pulse length) are selected so that the laser
effectively rounds and shapes the end face and helps remove
imperfections. The laser can also be used to process the end of the
ferrule to shape the ferrule, to impart structural features in to
the ferule (e.g., steps) or to ablate portions of the ferrule to
modify fiber protrusion lengths.
[0038] In other examples, a plasma treatment or other energy source
can be used to process the end face of the optical fiber and/or the
end of the ferrule. A typical plasma discharge is generally ball
shaped and is defined in the arc region between two electrodes.
Typically, the plasma discharge has a relatively small volume.
Thus, to provide coverage over the full end face of a ferrule or
fiber, it may be necessary to generate relative lateral movement
between the ferrule/fiber and the plasma discharge. This can be
accomplished by moving the energy source relative to the
ferrule/fiber or by moving the ferrule/fiber relative to the energy
source. In this way, the focal point of the energy source can be
scanned, indexed or otherwise manipulated across the end of the
ferrule or the fiber to provide full coverage or to provide desired
shaping at particular regions. It will be appreciated that the
shape of the plasma discharge may be altered to modify the
focal/active area of the discharge. In one example, air from one or
more sources can be directed at the plasma discharge to alter the
shape of the discharge. In certain examples, the shape of the
discharge can be widened to provide a larger coverage area during
ferrule/fiber processing. In certain examples, one or more streams
(e.g., currents) of air can be directed at the plasma discharge to
alter the discharge shape. The streams can be pulsed or continuous.
In the case of multiple streams, the streams of air can be directed
from opposite directions toward the discharge, can be directed from
the same direction toward the discharge, can be angled relative to
one another or can be parallel to one another. To control the
processing temperature at the ferrule or the fiber, one or more
heat sinks can be positioned adjacent to the distal end of the
fiber or the ferrule to draw heat away from the processing region.
Similarly, the non-contact energy source can be pulsed on and off
to prevent the processing temperature from exceeding a determined
level or to maintain the processing location at the ferrule/fiber
at a predetermined temperature. Pulsing allows for heat dissipation
between pulses.
[0039] FIGS. 1 and 2 illustrate one example ferrule assembly 20
which is suitable for practicing aspects of the present disclosure.
The ferrule assembly 20 includes a ferrule 22 and an optical fiber
24 secured to the ferrule 22. In one example, the ferrule 22 is
generally cylindrical. In one example, the ferrule has a diameter
in the range of 1-3 millimeters or in the range of 1.25-2.5
millimeters. Example ferrules include SC ferrules and LC ferrules.
The ferrule 22 includes a front end 26 positioned opposite from a
rear end 28. The front end 26 preferably includes an end face 30 at
which an interface end 32 of the optical fiber 24 is located. The
ferrule 22 defines a ferrule bore 34 that extends through the
ferrule 22 from the front end 26 to the rear end 28. The optical
fiber 24 includes a first portion 36 secured within the ferrule
bore 34 and a second portion 38 that extends rearwardly from the
rear end 28 of the ferrule 22. The first portion 36 of the optical
fiber 24 is preferably secured by an adhesive (e.g., epoxy) within
the ferrule bore 34 of the ferrule 22. The interface end 32
preferably includes a processed end face accessible at the front
end 32 of the ferrule 22.
[0040] The ferrule 22 is preferably constructed of a relatively
hard material capable of protecting and supporting the first
portion 36 of the optical fiber 24. In one embodiment, the ferrule
22 has a ceramic construction. In other embodiments, the ferrule 22
can be made of alternative materials such as Ultem, thermoplastic
materials such as Polyphenylene sulfide (PPS), other engineering
plastics or various metals. In one example, the ferrule 22 can be a
single fiber ferrule such as a ferrule for and SC connector, and ST
connector, or an LC connector. While FIGS. 1 and 2 depict a single
fiber ferrule, aspects of the present disclosure are also
applicable to multi-fiber ferrules such as MT-ferrules and MPO
ferrules. A typical multi-fiber ferrule can have a generally
rectangular shape and can support a plurality of optical fibers
supported in one or more rows by the multi-fiber ferrule.
[0041] The first portion 36 of the optical fiber 24 can include a
bare fiber segment 46 that fits within a first bore segment 40 of
the ferrule 22 and a coated fiber segment 48 that fits within a
second bore segment 42 of the ferrule 22. The bare fiber segment 46
is preferably bare glass and, as shown at FIG. 3, includes a core
47 surrounded by a if) cladding layer 49. In certain embodiments,
the coated fiber segment 48 includes one or more coating layers 51
surrounding the cladding layer 49 (see FIG. 4). In certain
embodiments, the coating layer or layers 51 can include a polymeric
material such as acrylate having an outer diameter in the range of
about 230-260 microns. In still other embodiments, the coating
layer/layers 51 can be surrounded by a buffer layer 53 (e.g., a
tight or loose buffer layer) (see FIG. 5) having an outer diameter
in the range of about 500-1100 microns.
[0042] FIGS. 6-10, 10A, 11 and 12 show a sequence of steps in
accordance with the principles of the present disclosure for
processing a ferrule assembly 20a including an optical fiber 24a to
be secured to the ferrule 22a. FIG. 6 shows the example ferrule 22a
including a ferrule body 60 having a distal end 62 and a proximal
end 64. The ferrule body 60 defines a fiber opening 66 that extends
axially through the ferrule body 60 from the proximal end 64 to the
distal end 62.
[0043] It will be appreciated that an interface end 32a (i.e., a
distal end face) of the optical fiber 24a has been pre-processed.
For example, the end of the optical fiber 24a has been cleaved
(e.g., mechanically or via a non-contact energy source such as a
laser). Also, the interface end 32a has been pre-processed to shape
(e.g., round as described above) the interface end 32a and to
remove imperfections. The pre-processing can include shaping steps
and imperfection removing steps of the type described previously
using mechanical polishing operations and/or non-contact energy
application operations of the type described above. Thus, the
optical fiber 24a depicted has a pre-processed end face 68 before
it is loaded into the ferrule 22a. It will be appreciated that the
ferrule 22a can also be pre-manufactured (e.g., molded, machined,
etc.) with a desired shaped, size and/or end-face
configuration.
[0044] As shown at FIG. 7, the fiber opening 66 of the ferrule body
60 has been filled with an adhesive 70 such as epoxy. An adhesive
injection process can be used to fill the fiber opening 66 with
adhesive. Once the opening 66 has been filled with the adhesive 70,
the optical fiber 24a can be inserted in a distal direction through
the fiber opening 66. FIG. 8 shows the optical fiber 24a after
insertion through the adhesive-filled opening 66 with the
pre-processed end face 68 extending distally past/beyond the distal
end 62 of the ferrule body 60. It will be appreciated that as the
optical fiber 24a is moved distally through the fiber opening 66,
at least some of the adhesive can be distally displaced from the
opening 66 and pushed out the distal end of the opening 66. This
displaced adhesive can be deposited on the distal end 62 of the
ferrule 60 and on the end face 68 of the optical fiber 24a. After
the optical fiber 24a has been fully inserted through the ferrule
22a, the optical fiber 24a can be retracted proximally relative to
the ferrule 22a so that the end face 68 of the optical fiber 24a is
slightly recessed relative to the distal end face of the ferrule
22a. A physical/mechanical wiping step can be used to remove at
least some of this displaced adhesive 70 from the distal end of the
ferrule 22a and the fiber end face 68. However, even after wiping,
at least some adhesive residue will typically remain on the fiber
end face 68 and on the distal end 62 of the ferrule 60.
[0045] After wiping of the adhesive, the optical fiber 24a can be
moved distally relative to the ferrule 22a to establish a desired
spatial relationship between the distal end of the ferrule 22a and
the distal tip of the optical fiber 24a. In this way, the optical
fiber 24a can be positioned within the fiber opening 66 such that
the pre-processed end face 68 of the optical fiber 24a is located
at a pre-determined axial position relative to the distal end 62 of
the ferrule body 60. In certain aspects, a flat plate 72 (e.g.,
optical flat) (see FIGS. 9 and 10) or other type of mechanical stop
may be used as a fiber stop to set/establish a desired axial
position of the optical fiber 24a relative to the distal end 62 of
the ferrule body 60. The stop can include a stop surface against
which the optical fiber tip abuts to stop distal movement of the
optical fiber 24a relative to the ferrule 22a at a desired
position. In one example, the mechanical stop can have a material
composition that includes sapphire. In one example, the flat plate
72 can define an opening 73 (see FIG. 10A) for allowing excess
adhesive 70 to pass therethrough as the optical fiber 24a is
inserted through the fiber opening 66. In certain aspects, this can
help to eliminate or reduce the need for the adhesive wiping step.
The fiber opening 66 can be smaller than a diameter of the bare
glass portion of the optical fiber 24a, but large enough to
accommodate at least some of the displaced adhesive from the fiber
opening 66. The stop surface of the plate 72 can have a predefined
distal offset from the end face of the ferrule 22a to stop the
distal tip of the optical fiber 24a at a desired distal projection
from the end face of the ferrule 22a. Alternatively, the stop
surface of the plate can be flush with the distal end face of the
ferrule 22a to stop the distal tip of the optical fiber 24a at a
flush spatial relationship relative to the distal end face of the
ferrule 22a. Further, the stop surface of the plate can project
into the fiber opening 66 of the ferrule 22a to stop the distal tip
of the optical fiber 24a at a proximally recessed spatial
relationship relative to the distal end face of the ferrule
22a.
[0046] Once the desired relative positioning between the ferrule
distal end 62 and the fiber end face 68 has been established, the
adhesive 70 is cured within the fiber opening 66 to axially fix the
optical fiber 24a within the fiber opening 66 such that the
pre-processed end face 68 of the optical fiber 24a is fixed at the
pre-determined axial position relative to the distal end 62 of the
ferrule body 60. In certain examples, plasma or other energy means
can be used to tack cure the adhesive 70 at the distal end 62 of
the ferrule body 60 to allow the process to proceed without having
to wait for a full adhesive cure time associated with ambient
temperature curing. The energy means can reduce the curing time by
heating the adhesive 70 (e.g., for a thermos-set adhesive) or by
applying radiation (e.g., ultraviolet radiation (UV)) in the case
of a radiation (e.g., UV) curable adhesive.
[0047] FIG. 11 shows the optical fiber 24a being exposed to a
non-contact energy source 74 (e.g., laser, plasma discharge arc,
infrared heat, etc.) to remove (e.g., ablate, vaporize, etc.)
excess adhesive 70 (i.e., adhesive residue) from the pre-processed
end face 68 of the optical fiber 24a (see FIG. 12). In certain
aspects, the excess adhesive 70 (i.e., adhesive residue) can also
be removed from the distal end 62 of the ferrule body 60 using the
non-contact energy source. This leaves a clean, undamaged ferrule
end face and fiber tip. The plasma discharges can be pulsed with
pauses between the discharges to control the temperature at the
distal end 62 of the ferrule body 60. In other aspects, one or more
heat sink structures may be used to transfer heat away from the
distal end 62. Epoxy within the fiber opening 66 between the
optical fiber 24a and the ferrule 22a is not removed because the
ferrule 22a provides thermal protection (i.e., thermal insulation
and isolation from the heat at the end face of the ferrule) that
prevents such adhesive from being heated to a temperature
sufficient to cause removal of the adhesive.
[0048] In certain aspects, the above process described with respect
to FIGS. 6-10, 10A, 11 and 12 can result in a final ferrule
assembly that does not require further processing. In other
examples, the above process describe with respect to FIGS. 6-12 can
be used in combination with one or more subsequent steps such as
polishing steps. For example, polishing can be used to further
shape the distal end face of the optical fiber 24a or remove
imperfections from the distal end face of the optical fiber 24a
after the adhesive 70 has been removed using a non-contact energy
source.
[0049] Certain aspects of the present disclosure are applicable to
ferrule assemblies that may include specialized optical fibers,
lenses, or other structures. In one example, aspects of the present
disclosure are applicable to a ferrule assembly including a ferrule
supporting a graded index (GRIN) lens adjacent the distal end of
the ferrule for allowing the ferrule assembly to function as part
of an expanded beam fiber optic connector. The GRIN lens can be
formed by a graded index optical fiber. It will be appreciated that
modifying the length of the graded index optical fiber modifies the
amount of expansion provided by the graded index optical fiber.
This can present an issue where polishing operations used to remove
adhesive from the end of the graded index optical fiber shorten the
length of the graded index optical fiber thereby modifying the
expansion level provided by the graded index optical fiber. By
using a non-contact energy source to remove adhesive from the end
of the graded index optical fiber, the adhesive can effectively be
removed without altering the length of the graded index optical
fiber. In this way, the expansion level provided by the graded
index optical fiber is not modified.
[0050] FIG. 13 shows an example ferrule assembly 20b suitable for
use in an expanded beam fiber optic connector. The ferrule assembly
20b can be processed using operations of the type disclosed herein.
In one example, the ferrule assembly 24b can include a ferrule 22b
supporting an optical fiber structure 24b. The optical fiber
structure 24b may include a beam expansion section 76 spliced to an
optical fiber 25 (e.g., a single mode optical fiber). The optical
fiber structure 24b is supported within the ferrule 22b and
positioned with an end face 78 of the beam expansion section 76
recessed within the ferrule 22b. The beam expansion section 76 has
a construction adapted to expand an optical beam from a first beam
diameter D1 to an enlarged second beam diameter D2 (see FIG. 13).
By recessing the end face 78 within the ferrule 22b, the ferrule
assembly 20b is less sensitive to damage associated with debris
(e.g., dust, sand, etc.) that may be trapped between the end faces
78 of two mated ferrule assemblies 20b in the field. For example,
in physical contact connectors where the end faces of the ferrules
abut when two ferrule assemblies are mated together, dust or sand
compressed between the fiber end faces can scratch or otherwise
damage the end faces. In contrast, because of the expanded beam
construction, two of the ferrule assemblies 20b do not need to have
physical contact between the end faces 78 of the optical fibers 24b
to provide an acceptable optical connection. By recessing the end
faces 78 relative to the distal ends of the ferrules 22b,
sufficient space can be provided when the end faces 78 during an
optical connection to accommodate dust/sand without damaging the
end faces 78. In one example, the distal tips of the optical fibers
are recessed 1-20 microns, or 5-20 microns, or 10-20 microns, or
greater than 1 micron, or greater than 5 microns, or greater than
10 microns relative to their respective ferrule end faces.
[0051] FIG. 13 depicts an example mode field configuration for the
optical fiber structure 24a. The optical fiber 25 has a core 47a
surrounded by a cladding 49a. The beam expansion section 76 of the
optical fiber 24a can be configured to expand a light beam
traveling in a first direction through the beam expansion section
76 and to focus a light beam traveling in an opposite second
direction through the beam expansion section 76. For example, the
beam expansion section 76 expands light traveling though the beam
expansion section 76 away from the optical fiber 25 and focuses
light traveling through the beam expansion section 76 toward the
optical fiber 25.
[0052] In certain examples, the beam expansion section 76 can
include a collimator for expanding/focusing light including, for
example, a lens or an expanded core of a fiber, in particular, a
thermally-expanded core. In certain examples, the beam expansion
section 76 can include a lens such as a graded index (GRIN) lens
(e.g., a graded index fiber). A GRIN lens may be made with a core
having a refractive index that varies generally parabolically as a
function of the radius. For example, the GRIN lens can have a
generally parabolic fiber refractive index profile that has a
maximum value at the center of the core and that gradually
decreases as the core extends radially away from the center of the
core.
[0053] The amount of expansion provided by a GRIN lens is highly
dependent upon the length of the GRIN lens. Thus, the length of the
GRIN lens should be precisely controlled. Typically, this would be
problematic in situations where a GRIN lens is provided at the end
face of a ferrule of a fiber optic connector because polishing of
the end face will alter the length of the GRIN lens thereby
changing the collimating or focusing properties provided by the
GRIN lens. However, this issue is overcome by the principles of the
present disclosure because the optical fiber can be pre-processed
such that no further polishing is required. Further details about
the structure of a GRIN lens are disclosed at U.S. Pat. No.
7,031,567, which is hereby incorporated by reference in its
entirety.
[0054] Typically, maximum expansion in a GRIN lens is achieved at
quarter pitch and at each odd-integer multiple of the quarter pitch
length. As indicated above, the amount of expansion provided by the
GRIN lens is dependent upon its configuration and length. A quarter
pitch is one quarter of the length of a full sinusoidal period that
a light ray traverses in the lens. In certain examples, the length
of the pitch can be calculated by the following formula:
I pitch = .pi. n ? D NA ##EQU00001## ? indicates text missing or
illegible when filed ##EQU00001.2##
wherein n is the core refractive index, D is the physical core
diameter, and NA is the numerical aperture. In certain examples, NA
is in the range 0.11<NA<0.14. With the NA and the core index
of refraction known or selected, the core diameter determines the
pitch-length. The core diameter also establishes a beam expansion
factor. As indicated above, maximum beam expansion occurs at the
quarter pitch length and odd-integer multiples thereof. An example
length of a quarter pitch of a GRIN lens is about 0.5-0.8
millimeters depending on the requirements. A GRIN lens typically
has a length tolerance of about .+-.10 micrometers.
[0055] As used herein, "mode field" means the portion of an optical
fiber through which light passes during a transmission through the
optical fiber of a light signal having a predetermined wavelength.
It will be appreciated that the "mode field" of a given optical
fiber may vary depending upon the wavelength of the light signal
being transmitted therethrough. As used herein, the "mode field
area" is the transverse cross-sectional area of the mode field at a
given location of the optical fiber. The "mode field area" is
typically circular and defines a mode field diameter across the
mode field area. The mode field diameter can be defined as where
the power density is reduced to 1/e.sup.2 of the maximum power
density. The mode field area can also be referred to as a "spot
area" or "beam area" and the mode field diameter can also be
referred to as the spot size or beam width.
[0056] Referring to FIG. 15, a flow chart is illustrated showing
another example method 100 for processing an expanded beam type
ferrule assembly such as the ferrule assembly 20b. In this example,
the method includes operations 102, 104, 106, 108, 110, 112, 114
and 116.
[0057] Operation 102 of the method 100 relates to pre-processing a
distal end face of the optical fiber structure 24b so as to form
the optical fiber with a pre-processed end face 78. The beam
expansion section 76 can have a desired length after
pre-processing. In certain examples, the pre-processed end face 78
can be covered with an anti-reflective coating material 79.
[0058] Operation 104 is performed to provide (e.g., inject)
adhesive within a fiber opening 66b of the ferrule 22b. Operation
106 is performed to insert (e.g., distally push) the optical fiber
structure 24b with the pre-processed end face 78 fully through the
adhesive filled fiber opening 66b of the ferrule and then
retracting (e.g., proximally pulling) the optical fiber structure
24b back into the fiber opening 66b of the ferrule 22b such that
the beam expansion section 76 is recessed relative to the distal
end (e.g., end face) of the ferrule 22b. Operation 108 is performed
to remove excess adhesive from the distal end of the ferrule 22b
and the optical fiber structure 24b (e.g., via wiping).
[0059] After operation 108 has been completed, operation 110 is
performed to move (e.g., distally push) the optical fiber structure
24b distally relative to the ferrule 22b to establish a position of
the optical fiber structure 24b such that the beam expansion
section 76 is protruding from the distal end 62 of the ferrule 22b.
In other examples, the end face 78 of the beam expansion section 76
can be positioned flush with the distal end of the ferrule 22a.
Operation 112 follows operation 110. At operation 112, the ferrule
22b can be mated with a reference ferrule 22e (see FIG. 14) having
a reference fiber that is used as a mechanical stop for setting a
desired recess distance of the end face 78 of the beam expansion
section 76 relative to the distal end of the ferrule 22b. The
reference fiber protrudes a distance "x" beyond corresponding
ferrule end face of the reference ferrule 22e. When the ferrule
assembly 20b is mated with the reference ferrule 22e, the reference
fiber extends into the fiber opening 66b of the ferrule 22b thereby
displacing the optical fiber structure 24b back into the ferrule
22b by the distance "x". Thus, the distance "x" corresponds to a
desired recess distance of the end face 78 of the beam expansion
section 76 relative to the distal end face of the ferrule 22b. Once
the recess location of the end face 78 has been established, the
reference ferrule 22e is de-mated from the ferrule 22b. The
reference ferrule 22e and the protruding fiber may be covered with
a material that does not adhere to the adhesive. In other examples,
the ferrule with the protruding fiber may be a disposable (i.e.,
consumable) part of the manufacturing process.
[0060] Operation 114 follows operation 112. Operation 114 is
performed to cure the adhesive to fix the optical fiber structure
24b within the fiber opening 66b such that the end face 78 of the
beam expansion section 76 is axially fixed at the desired recess
location relative to the distal end of the ferrule 22b. Operation
116 follows operation 114. Operation 116 is performed to remove
excess adhesive 70 from the pre-processed end face 78 of the
optical fiber structure 24b using a non-contact energy source. In
certain examples, the energy source does not remove the pre-applied
anti-reflective coating from the end face 78. In other examples,
the anti-reflective coating is applied to the end face 78 of the
optical fiber structure 24b after the adhesive has been removed
from the end face by the non-contact energy source. In other
examples, the non-contact energy source may be used to remove
excess adhesive from the ferrule 22b.
[0061] Typically in a ferrule, the fiber core is rarely perfectly
centered within the ferrule due to manufacturing tolerances. The
offset distance between the center of the fiber core and the center
of the ferrule is the core offset. To optically connect two
connectors, they are inserted into an adapter having an alignment
sleeve that receives and co-axially aligns the ferrules. Ideally,
the cores of the fibers are co-axially aligned so that light can be
transmitted between the fibers. However, due to core offset, the
cores may not be co-axially aligned. For example, a worse-case
scenario is when the core offsets of connected ferrules are 180
degrees offset from one another.
[0062] In certain connectors, the connectors are "tuned" by
identifying the direction of core offset, and then assembling the
connectors so that the core offsets are always facing in the same
direction (e.g., the twelve o'clock position). In this way, when
two connectors are mated, the core offsets are aligned and the
worse-case scenario of the core offsets being 180 degrees offset
from one another will not occur. In an APC connector, the core
offset is taken into consideration so that the direction of the
core offset is oriented at a predetermined position relative to the
direction of the angle polish to provide a tuning function.
[0063] Referring to FIG. 16, a flow chart is illustrated showing a
process 200 for manufacturing a ferrule assembly 20c including a
ferrule 22c having an angled distal end face 62c. In one example,
the end face 62c is angled 4-12 degrees relative to a central axis
of the ferrule 22c. In one example, the ferrule 22c defines a
central passage opening 66c (i.e., a fiber passage) that extends
axially through the ferrule 22c from a proximal end 64c to the
distal end face 62c of the ferrule 22c. The ferrule assembly 20c
also includes an optical fiber 24c secured within the fiber passage
66c. The optical fiber 24c includes an interface end 32c positioned
at the distal end face 62c.
[0064] A first step 202 of the process 200 is an optional a
pre-processing step in which the interface end 32c of the optical
fiber 24c is processed. For example, the end of the optical fiber
32c can be cleaved (e.g., laser cleaved) and processed using a
non-contact energy source to provide a desired geometric shaping
and/or to remove imperfections. In a second step 204 of the process
200, adhesive is filled (e.g., injected) in the fiber opening 66c
defined by the ferrule 22c. In a third step 206 of the process 200,
the optical fiber 24c is inserted with the pre-processed end face
through the adhesive filled opening 66c of the ferrule 22c. The
optical fiber 24c can be positioned within the fiber opening 66c
such that the pre-processed end 32c of the optical fiber 24c is
located at a pre-determined axial position relative to the distal
end 62c of the ferrule 22c. In a fourth step 208 of the process
200, the adhesive is cured to fix the optical fiber 24c within the
fiber opening 66c such that the pre-processed end 32c of the
optical fiber 24c is fixed at the pre-determined axial position
relative to the distal end 62c of the ferrule 22c. In a fifth step
210 of the process 200, residual cured adhesive is removed from the
interface end 32c of the optical fiber 24c and/or the end 62 of the
ferrule 22c using a non-contact energy source of the type
previously described (e.g., plasma discharge, laser or other energy
source previously described). In a sixth step 212 of the process
200, a core offset direction of the optical fiber core of the
optical fiber 24c is determined relative to a central axis of the
ferrule 22c. The core offset direction can be determined visually
without interference from residual adhesive singe the adhesive has
already been removed using the non-contact energy source. In a
seventh step 214, the distal end 62c of the ferrule 22c is polished
at an angle (e.g., about 8 degrees) relative to the central axis of
the ferrule 22c with an orientation of the angle being determined
with respect to the core offset direction of the optical fiber core
determined in the previous step.
[0065] FIG. 17 outlines a process 300 in accordance with the
principles of the present disclosure for establishing an end face
geometry for an optical fiber and/or a cylindrical ferrule
supporting the optical fiber. The ferrule can define a central
fiber opening that extends axially through the ferrule from a
proximal end to a distal end face of the ferrule. The optical fiber
includes an interface end positioned at the distal end face of the
ferrule. In a first step 302 of the process 300, the fiber opening
defined by the ferrule is filled with adhesive (e.g., by an
injection process). In a second step 304 of the process 300, the
optical fiber is inserted with through the adhesive filled opening
of the ferrule. The optical fiber can be positioned within the
fiber opening such that the interface end the optical fiber is
located at a pre-determined axial position relative to the distal
end of the ferrule. Alternatively, the interface end of the fiber
need not be precisely positioned relative to the ferrule and can be
positioned generally to protrude from the ferrule end face. In one
example, the optical fiber end can be cleaved to a desired
protrusion length at a later step (e.g., after adhesive curing). In
a third step 306 of the process 300, the adhesive is cured. In a
fourth step 308 of the process 300, the distal end face of the
ferrule and the distal end of the optical fiber are polished using
one or more abrasive mechanical polishing steps. The mechanical
polishing steps can provide shaping of the fiber and/or the
ferrule, can provide imperfection removal of the fiber distal end
face and can assist in establishing a desired relative axial
position between the fiber tip and the ferrule end face (e.g., a
desired fiber tip protrusion length, a desired fiber tip recession
depth, or a flush configuration). A fifth step 310 after the fourth
step 308 of the process 300 includes using a non-contact energy
source (e.g., plasma discharge, laser or other energy source
previously described) to further process (e.g., finally process)
the optical fiber tip and/or the ferrule end face. For example, the
non-contact energy source can be used to shape the fiber tip,
re-flow the surface of the fiber tip or clean the surface of the
fiber tip. Shaping the fiber tip can include modifying the fiber
tip to include at least some curvature (e.g., shaping to a desired
fiber radius). In certain examples, the fiber tip and the ferrule
end are modified in shape so as to comply with industry standards
or parameters for end face geometry. In certain examples, the fiber
tip can be provided with at a least portion having a spherical
shape of a desired radius. In certain examples, re-flowing the
surface of the fiber tip can assist in reducing loss-inducing
imperfections in the surface. In certain examples, cleaning can
include removing contaminants (e.g., dust or other particles) from
the fiber tip surface. In certain example, the ferrule can also be
shaped to a desired radius using the non-contact energy source.
[0066] FIG. 18 outlines a process 400 in accordance with the
principles of the present disclosure for establishing end face
geometries for optical fibers 24d and/or a generally rectangular
multi-fiber ferrule 22d supporting the optical fibers 24d. A
ferrule assembly 20d including the multi-fiber ferrule 22d
supporting the optical fibers 24d is shown at FIGS. 19-21. The
multi-fiber ferule 22d includes parallel fiber openings 66d for
receiving the optical fibers 24d. The multi-fiber ferrule 22d
further includes alignment openings 67 that are parallel to the
fiber openings 66d. In a male version of the multi-fiber ferrule
22d, alignment pins are mounted in the alignment openings 67. In a
female version of the multi-fiber ferrule, the alignment openings
67 remain open so as to be configured to receive the alignment pins
of a mating male multi-fiber ferrule when the male and female
multi-fiber ferrules are coupled together.
[0067] In a first step 402 of the process 400, the fiber openings
66d defined by the ferrule 22d are filled with adhesive (e.g., by
an injection process). In a second step 404 of the process 400, the
optical fibers 24d are inserted with through the adhesive filled
openings 66d of the ferrule 22d. The optical fibers 24d can be
positioned within the fiber opening 66d such that the ends the
optical fibers 24d are located at a pre-determined axial position
relative to the distal end of the multi-fiber ferrule 22d. In a
third step 406 of the process 400, the adhesive is cured. In a
fourth step 408 of the process 400, residual adhesive at the distal
ends of the optical fibers 24d and/or at the distal end of the
multi-fiber ferrule 22d can be removed using a mechanical polishing
process or using a non-contact energy source (e.g., a plasma
discharge).
[0068] In a fifth step 508 of the process 500 which occurs after
the fourth step 506, a desired fiber protrusion length is
established for the optical fibers 24d from the distal end face of
the multi-fiber ferrule 24d. In one example, the protrusion length
is established by ablating away the distal end face of the ferrule
22d with a laser without ablating the optical fibers 24d. The laser
can also be used to shape the ferrule and/or provide structural
features (e.g., steps, recesses, etc.) at the distal end of the
multi-fiber ferrule 22d. In certain examples, pulsed fiber laser
devices can be used to generate the laser beams for use in ablating
the outer layers of the distal end of a ferrule without ablating
the optical fibers. An example series of laser devices suitable for
micro-machining ferrules in the manner described above include the
G3 RM/HS series 10-20 W pulsed fiber lasers which are sold by SPI
Lasers UK Ltd, of South Hampton, UK.
[0069] As described above, the lasers used in ablating the distal
surfaces of ferrules in accordance with the present disclosure
preferably have laser beam characteristics selected to allow the
laser beams to ablate the material of the ferrule 22d without
substantially ablating the optical fibers 24d potted within the
ferrule 22d. An example patent showing a multi-fiber ferrule having
a distal end face with peripheral portions of the end face recessed
relative to a central portion of the end face is shown in United
States Patent Application Publication No. US2005/0180702, which is
hereby incorporated by reference in its entirety. While the
examples described above use a laser in a micro-machining process
to remove portions of the ferrule, it will be understood that other
micro-machining techniques for removing/ablating the end material
of a ferrule can be used as well. For example, micro-mechanical
machining techniques using micro or nano-mechanical machining tools
(e.g., micro or nano mechanical cutting tools, latches, etc.) can
be used to remove portions of the ferrule end face to expose
desired fiber protrusion lengths. Micro or nano robotics may be
used to implement such micro-mechanical machining techniques. Also,
micro-machining techniques can use etching techniques such as
chemical or plasma etching. Other types of plasma based removal
techniques can also be used. Moreover, ablation tools using
electromagnetic wave-based energy streams (e.g., pulsed,
continuous) other than laser light can also be used.
[0070] In a sixth step 510 that occurs after the fifth step 508, a
non-contact energy source (e.g., plasma discharge, laser or other
energy source previously described) is used to further process
(e.g., finally process) the distal tips of the optical fibers 24d
and/or the distal end face of the ferrule 22d. For example, the
non-contact energy source can be used to shape the fiber tips,
re-flow the surface of the fiber tips or clean the surfaces of the
fiber tips. Shaping the fiber tips can include modifying the fiber
tips to include at least some curvature (e.g., shaping to a desired
fiber radius). In certain examples, the fiber tips and the ferrule
end are modified in shape so as to comply with industry standards
or parameters for end face geometry. In certain examples, the fiber
tips can be provided with at a least portion having a spherical
shape of a desired radius. In certain examples, re-flowing the
surface of the fiber tips can assist in reducing loss-inducing
imperfections in the surface. In certain examples, cleaning can
include removing contaminants (e.g., dust or other particles) from
the fiber tip surface. In certain example, portions of the ferrule
22d can also be shaped to a desired radius using the non-contact
energy source.
[0071] From the forgoing detailed description, it will be evident
that modifications and variations can be made without departing
from the spirit and scope of the disclosure.
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