Optical fiber splitter module and fiber optic array therefor

• US 20070003205A1
• Filed: 01/17/2006
• Published: 01/04/2007
• Est. Priority Date: 06/30/2005
• Status: Active Grant

• Current Assignee: Corning Optical Communications LLC (Corning Incorporated)
• Original Assignee: Corning Cable Systems LLC (Corning Incorporated)
• Inventors: Makrides-Saravanos, Elli, Saravanos, Costas, Szentesi, Otto
• Granted Patent: US 7,756,382 B2
• Time in Patent Office: Days
• US Class Current: 385/137
• CPC Class Codes: G02B 6/2804 forming multipart couplers without wavelength selective elements, e.g. "T" couplers, star couplers
• CPC Class Codes: G02B 6/3636 the mechanical coupling means being grooves G02B6/3652 takes precedence
• CPC Class Codes: G02B 6/3664 2D cross sectional arrangements of the fibres
• CPC Class Codes: G02B 6/368 with pitch conversion between input and output plane, e.g. for increasing packing density

Abstract

An optical fiber splitter has a higher density fiber optic array that allows for smaller packaging. The optical fibers that extend from the optical fiber splitter have one end connectorized and their spacin at the other end reduced, thereby eliminating components that were heretofore required. A method of making the fiber optic array includes interleaving the optical fibers to reduce the overall dimensions of the fiber optic array and the fiber optic splitter. A tool is used to reduce the spacing of the optical fibers in the fiber optic array.

Claims

1. A splitter module comprising:

a housing having a fist end, a second end, and an opening extending therebetween;

a splitter chip disposed within the housing;

a plurality of optical fibers having a first end and a second end, the first end of the plurality of optical fibers being attached to a first edge of the splitter chip, the second end of each of the plurality of optical fibers having an outer coating thereupon with an outer diameter between about five and about twenty times larger than a diameter of each of the plurality of optical fibers at the first end; and

at least one optical fiber ached to a second edge of the splitter chip and being in optical communication with each of the plurality of optical fibers extending from the first edge of the splitter chip.

2. The splitter module according to claim 1, wherein the at least one optical fiber attached to the second edge of the splitter chip is attached hereto by an optical ferrule.

3. The split module according to claim 1, further comprising a potting compound encasing the splitter chip within the housing.

4. The splitter module according to claim 1, wherein the plurality of optical fibers extend from the first end of the housing and the at least one optical fiber extends from the second end of the housing.

5. The splitter module according to claim 1, wherein the plurality of optical fibers and the at least one optical fiber extend from the first end of the housing.

6. The splitter module according to claim 1, further comprising a base member having a first edge, a second edge, and a central portion, the first edge of the base member being attached to the first edge of the splitter chip, the plurality of optical fibers being attached to the base member with the plurality of optical fibers in optical communication with the splitter chip and with the first end of the plurality of optical fibers extending from the first edge of the base member across the central portion of the base member and beyond the sod edge, the second end of the plurality of optical fibers being connectorized.

7. The splitter module according to claim 6, wherein the plurality of optical fibers are parallel to one another in a first portion adjacent the first edge and in a second portion adjacent the second edge, and the plurality of optical fibers being nonparallel to one another in the central portion of the base member.

8. The splitter module according to claim 6, further comprising a cover and wherein at least one of the cover and the base member has a plurality of v-grooves formed therein covering and separating the plurality of optical fibers adjacent the first edge of the base member.

9-13. -13. (canceled)

14. A method of assembling an interleaved fiber array, the fiber array having at least two pluralities of optical fibers, the optical fibers having a diameter, the method comprising the steps of:

providing a first plurality of optical fibers, each of the optical fibers having a first end and a second end and each of the optical fibers having a coating at the first end such that the diameter of the optical fibers at the first end is at least 3.5 times the diameter of the optical fibers at the second end, and the optical fibers generally being aligned in a first plane at he first end;

providing a second plurality of optical fibers, each of the optical fibers having a fist end and a second end and each of the optical fibers having a coating at t first end such that the diameter of the optical fibers at the first end is at least 3.5 times the diameter of the optical fibers at the second end, and the optical fibers generally being aligned in a second plane at the first end;

aligning the fist and second plurality of optical fibers relative to one another at the first end of the optical fibers such that each of the optical fibers of the first and second plurality of optical fibers is aligned in a plane orthogonal to the first and second planes and each of the orthogonal planes for each the optical fibers in the first and second pluralities of optical fibers are different from one another; and

interleaving the second ends of the optical fibers from the first and second pluralities of optical fibers into a third plane wherein an optical fiber from one plurality of optical fibers is not adjacent to another optical fiber from the same plurality of optical fibers.

15. The method of claim 14, wherein the third plane is the same as the first plane.

16. The method of claim 14, wherein the first and second plurality of optical fibers are comprised of optical fibers that are interleaved optical fibers from a third and fourth plurality of optical fibers.

17. The method of claim 14, further comprising the step of reducing the spacing between each of the optical fibers at their second ends such that the spacing between each optical fiber is less than 10% of the diameter of optical fibers at the second end.

18. The method of claim 14, wherein the diameter of the optical fibers at the first end is at least 14 times the diameter of the optical fibers at the second end.

19. A tool for reducing the horizontal and vertical spacing between optical fibers comprising:

an upper surface defining a length and a depth; and

at least two side surfaces extending into the upper surface to create a cavity therein, the side surfaces generally extending toward one another along at least a portion of the length of the upper surface thereby creating a generally V-shaped configuration, the cavity having a depth of at least 130 microns.

20. The tool of claim 19, wherein the depth of cavity varies between 130 microns and 250 microns.

21. A tool for reducing spacing between optical fibers comprising:

a base member having a front face and a rear face; and

an opening in the base extending between front face and the rear face, the opening defining a depth and a width, the width of the opening decreasing between the front face and the rear face.