Overlapping fusion attenuator

• US 5,588,087 A
• Filed: 09/14/1994
• Issued: 12/24/1996
• Est. Priority Date: 01/02/1992
• Status: Expired due to Term

• Current Assignee: ADC Telecommunications Incorporated (TE Connectivity Limited)
• Original Assignee: ADC Telecommunications Incorporated (TE Connectivity Limited)
• Inventors: Lu, Liang-Ju, Emmons, David J.
• Primary Examiner(s): Lee, John D.
• Application Number:
  US08/306,241
• Time in Patent Office: 832 Days
• Field of Search: 385/140, 385/96
• US Class Current: 385/140
• CPC Class Codes: G02B 6/266 the optical element being an attenuator
• CPC Class Codes: G02B 6/2835 formed or shaped by thermal treatment, e.g. couplers

Abstract

A method for fabricating an optical attenuator from first and second optical fibers includes placing the fibers in closely spaced overlapped relation to define an overlapped portion of the fibers. Energy is initially applied to the overlapped portion to at least partially fuse the first and second fibers at the overlapped portion.

Claims

1. A method for fabricating an optical attenuator from at least a first and a second optical fiber having first and second claddings, respectively, surrounding first and second cores, respectively, and each of said first and second fibers having longitudinally extending axes extending coaxially with said cores, said method comprising the steps of:

placing said first and second fibers with said axes of said fibers in closely-spaced overlapping relation to define an overlapped portion of said fibers;

applying thermal energy to said overlapped portion to at least partially fuse said first and second fibers at said overlapped portion; and

holding said fibers for said fibers to be in general axial alignment following fusion of said overlapped portion.

2. A method according to claim 1 wherein said placing step includes disposing said fibers in side-by-side abutting relation at said overlapped portion.

3. A method according to claim 1 wherein said placing step includes placing said fibers in parallel alignment at said overlapped portion.

4. A method according to claim 1 comprising applying said energy to move said cores toward one another.

5. A method for fabricating an optical attenuator from at least a first and a second optical fiber having first and second claddings, respectively, surrounding first and second cores, respectively, and each of said first and second fibers having longitudinally extending axes extending coaxially with said cores, said method comprising the steps of:

placing said first and second fibers with said axes of said fibers in closely-spaced overlapping relation to define an overlapped portion of said fibers;

applying thermal energy to said overlapped portion to at least partially fuse said first and second fibers at said overlapped portion to form a fused overlapped portion; and

measuring an attenuation through said fused overlapped portion.

6. A method according to claim 5 further comprising applying an additional application of energy to said overlapped portion after said measuring and measuring said attenuation after said additional application.

7. A method according to claim 6 further comprising performing subsequent additional applications of energy to said overlapped portion followed by subsequent additional measurement of said attenuation until a measured attenuation achieves a desired attenuation.

8. A method according to claim 5 wherein said placing includes disposing said fibers in side-by-side abutting relation at said overlapped portion.

9. A method for fabricating an optical attenuator from at least a first and a second optical fiber having first and second claddings, respectively, surrounding first and second cores, respectively, and each of said first and second fibers having longitudinally extending axes extending coaxially with said cores, said method comprising the steps of:

placing said first and second fibers with said axes of said fibers in closely-spaced overlapping relation to define an overlapped portion of said fibers;

initially applying thermal energy to said overlapped portion to at least partially fuse said first and second fibers at said overlapped portion; and

wherein said placing step includes placing a first and second anchor location of said first and second fibers, respectively, in relative positioning with axes of said first and second cores offset at said first and second anchor locations;

and urging said first and second cores at said first and second anchor locations toward an axial alignment.

10. A method according to claim 9 wherein said placing includes disposing said fibers in side-by-side abutting relation at said overlapped portion.

11. A method for fabricating an optical attenuator from at least a first and a second optical fiber having first and second claddings, respectively, and each of said first and second fibers having longitudinally extending axes extending coaxially with said cores, surrounding first and second cores, respectively, said method comprising the steps of:

placing said first and second fibers with said axes of said fibers in closely-spaced overlapping relation to define an overlapped portion of said fibers;

initially applying thermal energy to said overlapped portion to at least partially fuse said first and second fibers at said overlapped portion; and

forming a reduced diameter portion on at least one of said first and second claddings and, in said placing step, positioning said reduced diameter portion at said overlapped portion.

12. A method according to claim 11 wherein said placing includes disposing said fibers in side-by-side abutting relation at said overlapped portion.

13. A method for fabricating an optical attenuator from at least a first and a second optical fiber having first and second claddings, respectively, and each of said first and second fibers having longitudinally extending axes extending coaxially with said cores, surrounding first and second cores, respectively, said method comprising the steps of:

placing said first and second fibers with said axes of said fibers in closely-spaced overlapping relation to define an overlapped portion of said fibers; and

applying thermal energy to said overlapped portion to at least partially fuse said first and second fibers substantially throughout said overlapped portion.

14. A method according to claim 13 wherein said placing includes disposing said fibers in side-by-side abutting relation at said overlapped portion.

15. A method for fabricating a fiber optic attenuator comprising the steps of:

providing first and second fiber segments, each segment having a first end and a second end, a portion of each segment including the first end being referred to as a first end portion, the fiber segments being characterized by a fiber diameter and the first end portions having respective radially outer surfaces;

bringing the respective first end portions of the fiber segments into a relative position such that the radially outer surfaces of the respective first end portions contact each other and the respective first end portions overlap by an axial distance greater than the fiber diameter;

heating the respective first end portions so that they assume a plastic state;

adjusting the relative axial positioning of the respective first end portions while the respective first end portions are in the plastic state to achieve a desired degree of attenuation; and

cooling the respective first and end portions to form a fused splice.

16. The method of claim 15 wherein the axial distance is in the range of about 0.5-5.0 mm.

17. The method of claim 15 wherein the axial distance is in the range of 1-3 mm.

18. The method of claim 15, and further comprising the step of injecting light into the second end of the first fiber segment and monitoring the light that emerges from the second end of the second fiber segment, and wherein said adjusting step is performed in response to the monitored light.

19. A fiber optic attenuator comprising:

first and second fiber segments, each having respective first and second ends, a portion of each segment including the first end being referred to as a first end portion, said fiber segments being characterized by a fiber diameter;

said respective first end portions being fused to each other and overlapping each other in an overlap region by an axial distance that is greater than said fiber diameter, said respective second ends being located on longitudinally opposite sides of said overlap region.

20. The attenuator of claim 19 wherein said fiber segments are single-mode fiber.

21. The attenuator of claim 20 wherein the attenuator is characterized by an attenuation greater than about 3 dB.

22. The attenuator of claim 19 wherein said fiber segments are multimode fiber.

23. The attenuator of claim 22 wherein the attenuator is characterized by an attenuation greater than about 10 dB.

24. A fiber optic attenuator comprising:

first and second segments, each having respective first and second ends, a portion of each segment including the first end being referred to as a first end portion, said fiber segments being characterized by a fiber diameter and having respective cores having respective ends;

said respective first end portions being fused to each other with said ends of said cores completely encapsulated and overlapping each other in an overlap region by an axial distance that is greater than said fiber diameter, said respective second ends being located on longitudinally opposite sides of said overlap region.

25. The attenuator of claim 24 wherein said fiber segments are single-mode fiber.

26. The attenuator of claim 25 wherein the attenuator is characterized by an attenuation greater than about 3 dB.

27. The attenuator of claim 24 wherein said fiber segments are multimode fiber.

28. The attenuator of claim 27 wherein the attenuator is characterized by an attenuation greater than about 10 dB.

29. A method for fabricating a fiber optic attenuator comprising the steps of:

providing first and second fiber segments, each segment having a first end and a second end, a portion of each segment including the first end being referred to as a first end portion, the fiber segments being characterized by a fiber diameter and the first end portions having respective radially outer surfaces;

bringing the respective first end portions of the fiber segments into a relative position such that the radially outer surfaces of the respective first end portions contact each other and the respective first end portions overlap in an overlap region by an axial distance greater than the fiber diameter with said respective second ends being located on longitudinally opposite sides of said overlap region;

heating the respective first end portions so that they assume a plastic state;

adjusting the relative axial positioning of the respective first end portions while the respective first end portions are in the plastic state to achieve a desired degree of attenuation; and

cooling the respective first end portions to form a fused splice.

30. The method of claim 29 wherein the axial distance is in the range of about 0.5-5.0 mm.

31. The method of claim 29 wherein the axial distance is in the range of 1-3 mm.

32. The method of claim 29, and further comprising the steps of injecting light into the second end of the first fiber segment and monitoring the light that emerges from the second end of the second fiber segment, and wherein said adjusting step is performed in response to the light, so monitored.