Direct-Connect Optical Splitter Module

• US 20100150501A1
• Filed: 02/23/2010
• Published: 06/17/2010
• Est. Priority Date: 05/31/2007
• Status: Active Grant

• Current Assignee: Corning Optical Communications LLC (Corning Incorporated)
• Original Assignee: Corning Optical Communications LLC (Corning Incorporated)
• Inventors: Rief, Angela, Schwelker, Wolfgang, Melnelt, Markus, Hartkorn, Klaus, Cox, Terry Dean
• Granted Patent: US 9,513,445 B2
• Time in Patent Office: Days
• US Class Current: 385/48
• CPC Class Codes: G02B 2006/12102 Lens
• CPC Class Codes: G02B 2006/1215 Splitter
• CPC Class Codes: G02B 6/02357 Property of longitudinal structures or background material varies radially and/or azimuthally in the cladding, e.g. size, spacing, periodicity, shape, refractive index, graded index, quasiperiodic, quasicrystals
• CPC Class Codes: G02B 6/125 Bends, branchings or intersections
• CPC Class Codes: G02B 6/30 for use between fibre and thin-film device
• CPC Class Codes: G02B 6/3845 ferrules comprising functional elements, e.g. filters
• CPC Class Codes: G02B 6/3885 Multicore or multichannel optical connectors, i.e. one single ferrule containing more than one fibre, e.g. ribbon type optical ribbon cable G02B6/4403, G02B6/448

Abstract

A compact optical splitter module is disclosed. One type of compact optical splitter module is a planar attenuated splitter module that includes a branching waveguide network having j≧1 50:50 splitters that form up to n≦2^j output waveguides having associated n output ports, wherein only m<n output ports are suitable for transmitting light to the at least one external output device. This provides a 1×m splitter module wherein each output port has the attenuation of a 1×n splitter module, thereby obviating the need for external attenuation. Another type of compact optical splitter module is a direct-connect splitter module that eliminates the need for an optical fiber array when coupling to external optical fibers. Another type of compact optical splitter module is a microsplitter module that serves as device and module at the same time and that eliminates the differentiation between device and module. The integration of device and module also makes manufacturing the microsplitter module cost-effect. Embodiments of microsplitter modules that account for differences in the coefficient of thermal expansion of the materials making up the microsplitter are also disclosed.

Claims

1. A direct-connect splitter module for providing optical communication with at least one external output device via a module output end, comprising:

a ferrule having a central axis, adjacent input-end and output-end sections that include respective input and output ends and that respectively include connecting input and output channels that run along the central axis and that have respective open ends at the respective input and output ends;

a splitter chip that includes input and output ends and a branching waveguide network that includes at least one input waveguide at its input end and at least two output waveguides each having an output end at the splitter chip output end, wherein the splitter chip is fixed in the output channel of the ferrule with its output end at the output channel open end;

at least one input ferrule connected to the input end of the splitter chip and that resides in the input-end channel;

at least one input optical fiber having an output end and an input end that is optically coupled to the at least one input waveguide of the splitter chip via the at least one input ferrule;

a thermosetting resin that substantially fills the input channel so as to fix the at least one input ferrule and the at least one input optical fiber in position within the input-end channel; and

a housing generally surrounding at least a portion of the ferrule so as to cover the input end of the input-end channel and to provide conformity with a connector associated with the at least one external output device and to contain the thermosetting resin in the input end,

wherein the splitter module provides for direct connection to the at least one external output device.

2. The direct-connect splitter module of claim 1, wherein at least a portion of the input end of the splitter chip resides within the input channel so that said portion is held in place within the input channel by the thermosetting resin.

3. The direct-connect splitter module of claim 1, wherein the output-end channel has a bottom wall and opposing sidewalls, and wherein the splitter chip is closely arranged and fixed in the outer-end channel by a layer of adhesive between the splitter chip and the bottom wall and/or opposing sidewalls.

4. The direct-connect splitter module of claim 1, wherein the ferrule output end includes at least one guide member that facilitates connecting the module to the at least one external output device.

5. The direct-connect splitter module of claim 1, wherein the corresponding output ends of the ferrule and the splitter chip are formed such that the module output end is compatible with an MTP-type connector.

6. The direct-connect splitter module of claim 1, wherein the input-end channel has a channel width W_I, the output-end channel has a channel width W_O, and wherein W_I>

W_O.

7. The direct-connect splitter module of claim 1, including the at least one external output device as optically coupled to at least one of the output waveguides of the splitter chip.

8. The direct-connect splitter module of claim 7, including an external input device optically coupled to the at least one input optical fiber input end.

9. The direct-connect splitter module of claim 1, including a single input optical fiber and a single input waveguide.

10. The direct-connect splitter module of claim 1, including an external connector having connector waveguides, wherein the external connector is optically coupled to the module output end so that the connector waveguides are optically coupled to the splitter chip output waveguides.

11. A direct-connect splitter module for providing optical communication with at least one external output device via a module output end, comprising:

a ferrule having a central axis, adjacent input-end and output-end sections that include respective input and output ends and that respectively include connecting input and output channels that run along the central axis and that have respective open ends at the respective input and output ends;

a splitter chip that includes input and output ends and a branching waveguide network that includes at least one input waveguide at its input end and at least two output waveguides each having an output end at the splitter chip output end, wherein the splitter chip is fixed in the output channel of the ferrule with its output end at the output channel open end;

at least one input ferrule connected to the input end of the splitter chip and that resides in the input-end channel;

at least one input optical fiber having an output end and an input end that is optically coupled to the at least one input waveguide of the splitter chip via the at least one input ferrule; and

a housing and generally surrounding at least a portion of the ferrule so as to cover the input end of the input-end channel and wherein the housing has a section at the output end of the splitter module to provide conformity with a connector associated with the at least one external output device,

wherein the splitter module provides for direct connection to the at least one external output device.

12. The direct-connect splitter module of claim 11, wherein the output-end channel has a bottom wall and opposing sidewalls, and wherein the splitter chip is closely arranged and fixed in the outer-end channel by a layer of adhesive between the splitter chip and the bottom wall and/or opposing sidewalls.

13. The direct-connect splitter module of claim 11, wherein the ferrule output end includes at least one guide member that facilitates connecting the module to the at least one external output device.

14. The direct-connect splitter module of claim 11, wherein the corresponding output ends of the ferrule and the splitter chip are formed such that the module output end is compatible with an MTP-type connector.

15. The direct-connect splitter module of claim 11, wherein the input-end channel has a channel width W_I, the output-end channel has a channel width W_O, and wherein W_I>

W_O.

16. The direct-connect splitter module of claim 11, including the at least one external output device as optically coupled to at least one of the output waveguides of the splitter chip.

17. The direct-connect splitter module of claim 16, including an external input device optically coupled to the at least one input optical fiber input end.

18. The direct-connect splitter module of claim 11, including a single input optical fiber and a single input waveguide.

19. The direct-connect splitter module of claim 11, including an external connector having connector waveguides, wherein the external connector is optically coupled to the module output end so that the connector waveguides are optically coupled to the splitter chip output waveguides.

20. A splitter module, comprising;

a splitter chip assembly having a body wherein the body comprises a planar splitter chip and a planar glass cover;

an input ferrule attached to an input end of the planar splitter chip;

a branching waveguide network having an input waveguide and output waveguides, wherein the input ferrule provides optical coupling between an input optical fiber and the input waveguide;

a connector sleeve having an open end that opens to an interior of the splitter module and that covers the input ferrule, wherein the connector sleeve is adapted to facilitate optically connecting input optical fiber to an external optical fiber cable; and

a multi-fiber ferrule having a body that supports a plurality of output optical fibers, each of the plurality of output optical fibers comprising an output optical fiber input end and an output optical fiber output end, wherein the plurality of optical fibers are disposed in holes in the multi-fiber ferrule, and wherein the holes are formed to have a same pitch as the output waveguides such that the output optical fiber output ends have the same pitch as the output waveguides.

21. The splitter module of claim 20, wherein the multi-fiber ferrule is attached to an output end of the planar splitter chip, wherein the output waveguides are optically coupled to the output optical fiber input ends.

22. The splitter module of claim 20, further comprising a housing, wherein the housing contains a portion of one or more of the input ferrule, the multi-fiber ferrule and the splitter chip assembly.

23. The splitter module of claim 22, wherein the housing is molded to conform to a multi-fiber connector to be used with the module.

24. The splitter module of claim 22, wherein the housing supports one or more of the input ferrule, the multi-fiber ferrule, and the splitter chip assembly, and wherein the housing maintains the input ferrule, the multi-fiber ferrule, and the splitter chip assembly in mutual alignment.

25. The splitter module of claim 22, wherein the housing comprises a boot section, and wherein the input ferrule and the input optical fiber are positioned in the boot section in a pigtail configuration.

26. The splitter module of claim 20, further comprising a fiber array positioned between the splitter chip and the multi-fiber ferrule.

27. The splitter module of claim 20, further comprising a fiber assembly having a fiber assembly input end and a fiber assembly output end positioned between the splitter chip and the multi-fiber ferrule, wherein the fiber assembly includes at least one glass plate to support the output fibers.