Arrangement for automated fabrication of fiber optic devices

• US 5,970,749 A
• Filed: 08/21/1997
• Issued: 10/26/1999
• Est. Priority Date: 12/10/1996
• Status: Expired due to Fees

• Current Assignee: Cary Bloom
• Original Assignee: Cary Bloom
• Inventors: Bloom, Cary
• Primary Examiner(s): HOFFMANN, JOHN M
• Application Number:
  US08/916,177
• Time in Patent Office: 796 Days
• Field of Search: 65/378, 65/381, 65/411, 65/409, 65/501
• US Class Current: 65/378
• CPC Class Codes: G02B 6/2551 using thermal methods, e.g. fusion welding by arc discharge, laser beam, plasma torch
• CPC Class Codes: G02B 6/2835 formed or shaped by thermal treatment, e.g. couplers
• CPC Class Codes: G02B 6/362 Vacuum holders for optical elements
• CPC Class Codes: G02B 6/3636 the mechanical coupling means being grooves G02B6/3652 takes precedence
• CPC Class Codes: G02B 6/3652 the additional structures being prepositioning mounting areas, allowing only movement in one dimension, e.g. grooves, trenches or vias in the microbench surface, i.e. self aligning supporting carriers
• CPC Class Codes: G02B 6/3837 forwarding or threading methods of light guides into apertures of ferrule centering means
• CPC Class Codes: G02B 6/3855 characterised by the method of anchoring or fixing the fibre within the ferrule G02B6/3854 takes precedence
• CPC Class Codes: G02B 6/3861 Adhesive bonding adhesives in general C09J
• CPC Class Codes: G02B 6/3862 radially-compressed, longitudinally-split ferrules consisting of a pair of identical matching halves
• CPC Class Codes: G02B 6/4248 Feed-through connections for the hermetical passage of fibres through a package wall see provisionally also G02B6/4428

Abstract

Fiber optic devices are manufactured in an automated environment using a combination of clamps to secure the optical fibers and movable gripping devices that transport the optical fiber during the fabrication process while maintaining control of the ends of the optical fibers. An optical fiber from a spool is removed by a despooling arm having a gripping device, and moveable grippers thread the optical fiber into a set of clamps and place the end of the optical fiber in a clamp designed to splice the fiber optic end to a lead of a testing device. The fiber optic device is formed by dynamically controlling the heating and pulling process based on detected coupling ratios, and hermetically sealed while secured within the clamps. The sealed fiber optic device is moved for testing or packaging using a transport arm having a series of clamps to maintain the position of the fiber optic device and the ends of the leads of the fiber optic device.

Claims

1. A method of automating fabrication of a fiber optic device, comprising:

securing an end of a first optical fiber into a stationary gripping device;

transferring the end of the first optical fiber to one of a plurality of movable gripping devices;

moving the end of the first optical fiber along a prescribed path using at least the one movable gripping device, the prescribed path coinciding with positions of at least one device to be threaded by the first optical fiber and primary clamps mounted on first and second stages, respectively;

securing the first optical fiber to the two primary clamps;

applying incident heat on the first optical fiber between the two primary clamps with a heat source;

selectively moving the stages along an optical fiber axis to pull the heated first optical fiber at a pulling velocity;

detecting at the end of the first optical fiber an optical characteristic of the first optical fiber;

controlling the incident heat and the pulling velocity on the first optical fiber, based on a change in the detected optical characteristic, to form the fiber optic device;

hermetically sealing the fiber optic device while maintaining a prescribed position of the end of the fiber optic device;

securing the fiber optic device to a transport device relative to the end of the first optical fiber and a cut end of the first optical fiber; and

moving the fiber optic device from the primary clamps and the movable gripping devices while maintaining a prescribed position of the end and the cut end of the fiber optic device relative to the transport device.

2. The method of claim 1, wherein the moving step comprises:

moving the end of the first optical fiber along a first segment of said prescribed path using the one movable gripping device;

handing off the end of the first optical fiber from the one movable gripping device to a first adjacent movable gripping device;

moving the end of the first optical fiber along a second segment of said prescribed path and through the at least one device to be threaded using the adjacent movable gripping device; and

handing off the end from the adjacent movable gripping to a second movable gripping device adjacent to the first adjacent movable gripping device.

3. The method of claim 1, wherein the first optical fiber is a coated optical fiber, the method further comprising:

securing the coated first optical fiber to secondary clamps movably positioned on the first and second stages, respectively, the primary clamps on the first and second stages positioned between the corresponding secondary clamps;

stripping the coated optical fiber to expose a segment of the optical fiber; and

wherein the primary clamps securing step comprises securing the exposed segment of the first optical fiber to the two primary clamps.

4. The method of claim 3, further comprising:

securing an end of a second coated optical fiber into a second stationary gripping device;

transferring the end of the second coated optical fiber to one of a second plurality of movable gripping devices;

moving the end of the second coated optical fiber along at least a portion of said prescribed path including said at least one device and said primary clamps;

securing the second coated optical fiber to a second set of secondary clamps movably positioned on the first and second stages, respectively, the primary clamps on the first and second stages positioned between the corresponding second set of secondary clamps;

stripping the second coated optical fiber to expose a segment of the second optical fiber; and

securing the exposed segment of the second optical fiber to the two primary clamps.

5. The method of claim 1, wherein the primary clamps securing step comprises:

placing an exposed portion of the first optical fiber within each of the primary clamps;

imparting a suction force on the first optical fiber within each of the primary clamps;

covering each of the primary clamps with a clamp housing having a segment for engagement with the exposed portion of the optical fiber; and

imparting a second suction force on each clamp housing from the corresponding primary clamp.

6. The method of claim 1, further comprising:

securing the first optical fiber to secondary clamps movably mounted on the first and second stages, the primary clamps positioned between the secondary clamps;

releasing the first optical fiber from one of the secondary clamps;

moving the threaded device along the first optical fiber and across the one released secondary clamp to a position between the released secondary clamp and the corresponding primary clamp;

reclamping the first optical fiber in the released secondary clamp;

releasing the first optical fiber from the primary clamp adjacent to the moved threaded device;

moving the threaded device along the first optical fiber and across the one released primary clamp to a position between the primary clamps; and

reclamping the first optical fiber in the released primary clamp.