Low profile system for joining optical fiber waveguides

• US 7,255,498 B2
• Filed: 06/29/2006
• Issued: 08/14/2007
• Est. Priority Date: 03/24/2003
• Status: Expired due to Fees

• Current Assignee: Andrew Vellrath, Cheng P. Ma, John A. Crowell, Laurence N. Wesson, Nellie L. Cabato, Simon P. Bush
• Original Assignee: Andrew Vellrath, Cheng P. Ma, John A. Crowell, Laurence N. Wesson, Nellie L. Cabato, Simon P. Bush
• Inventors: Vellrath, Andrew, Ma, Cheng P., Wesson, Laurence N., Bush, Simon P., Crowell, John A., Cabato, Nellie L.
• Primary Examiner(s): KIANNI, KAVEH C
• Application Number:
  US11/477,318
• Publication Number:
  US 20060266082A1
• Time in Patent Office: 411 Days
• Field of Search: 385/96, 385/95, 385/97
• US Class Current: 385/96
• CPC Class Codes: G01M 11/37 in which light is projected perpendicularly to the axis of the fibre or waveguide for monitoring a section thereof
• CPC Class Codes: G02B 6/2551 using thermal methods, e.g. fusion welding by arc discharge, laser beam, plasma torch
• CPC Class Codes: G02B 6/2555 Alignment or adjustment devices for aligning prior to splicing

Abstract

A compact, low profile splicing system for joining optical fibers produces durable, low transmission loss fusion splices. The system employs active optical techniques such as profile alignment or local injection and detection to achieve optimized alignment of the fibers prior to fusion. Light injected into one fiber is propagated across the interface to a second fiber. A detector senses the intensity of the injected light in the second fiber. After the relative position of the fibers is manipulated to maximize the transmitted intensity, the fibers are fusion spliced using an electric arc discharge. The accurate alignment achievable using the local injection and detection system to drive adaptive fiber positioning affords a method for reliably producing low loss splices. The present system is compact and low in profile, making it operable in cramped quarters with limited clearance to adjacent equipment and structures and with only a minimal amount of free fiber slack available. Simplicity of design and operation make the system rugged and enable accurate alignment and low loss fusion of fibers under adverse working conditions.

Claims

1. A method for joining a first optical fiber and a second optical fiber along a common fiber axis, the method comprising:

a) providing a low profile fusion splicing system, the system comprising;

(i) a low profile fusion splicing head having a fusion splicing stage including a clamping and fiber position adjustment system comprising holding means for holding said fibers substantially in a horizontal plane and motion means for moving said fibers in three orthogonal dimensions into coaxial, abutting alignment;

an imaging optical system having a fiber imaging illuminator and a fiber image detector, said imaging optical system being adapted to acquire optical images of said fibers in a first imaging direction and a second imaging direction, said imaging directions being non-coincident; and

an electric arc welding system;

(ii) a user interface having an output display and user input controls for activating the splicing system;

(iii) electronic control circuitry having imaging electronics that receive the output of said fiber image detector and produce a display signal feeding said output display; and

fusion control electronics operably connected to activate said electric arc welding system and supply high voltage thereto;

b) preparing said first and second optical fibers by removing coatings present thereon and cleaving the ends of the fibers to form a mating end on each fiber;

c) arranging said first and second optical fibers in said holding means with said mating ends in facing relationship;

d) imaging said fibers in said imaging optical system prior to said joining;

e) positioning said optical fibers into coaxial, abutting alignment; and

f) transmitting light from a first source traverses a first optical path and transmitting light from a second source traverses a second optical path, each of said paths being multiply folded;

g) fusing said fibers by said electric arc welding system.

2. A method as recited by claim 1, wherein said arranging comprises clamping said fibers in V-blocks comprised in said holding means in said fusion head.

3. A method as recited by claim 2, wherein said holding means comprises a first and a second removable clamp assembly.

4. A method as recited by claim 3 wherein:

said fibers are mounted in said removable clamp assemblies prior to said preparing of said fibers;

said preparing of said fibers is carried out using an auxiliary fiber preparation apparatus; and

said arranging comprises placing said removable clamp assemblies bearing said fibers in said fusion splicing system.

5. A method as recited by claim 1, wherein said electronic control circuitry further comprises a profile alignment system in communication with said fiber image detector and said positioning comprises use of said profile alignment system to command said motion means to bring said fibers into alignment.

6. A method as recited by claim 1, wherein:

a. said fusion splicing head further comprises a local injection and detection system including a light injector adapted to inject light into said first fiber and a light detector detecting light in said second fiber, said local injection and detection system providing an electronic intensity signal indicative of the fraction of said injected light propagated across the interface between said fibers;

b. said electronic control circuitry further comprises a driver energizing said light injector and measurement electronics connected to said light detector receiving and processing said electronic intensity signal to provide a measured intensity signal; and

a servo system operative to drive said actuators to maximize said measured intensity signal, whereby the position of said fibers is optimized prior to fusion thereof;

c. said method further comprises mounting said first optical fiber in said light injector and said second optical fiber in said light detector; and

d. said positioning comprises use of said servo system to command said motion means to bring said fibers into alignment.

7. A method as recited by claim 6, wherein said light injected by said light injector has a wavelength ranging from about 800 to 900 nm.

8. A method as recited by claim 1, wherein said positioning comprises translation of said fibers in three mutually orthogonal directions.

9. A method as recited by claim 8, wherein one of said mutually orthogonal directions is substantially coincident with said common fiber axis.

10. A method as recited by claim 8, wherein said positioning comprises translation of said first fiber in a first transverse direction substantially orthogonal to said fiber direction and translation of said second fiber in a second transverse direction substantially orthogonal to said fiber direction and said first transverse direction.

11. A method as recited by claim 1, further comprising inferring the transmission loss of said fiber after said fusing.

12. A method as recited by claim 1, further comprising encasing said fused joint in a heat shrinkable sheath.

13. A method as recited by claim 1, further comprising storing and transferring data associated with said joining.