ARRANGEMENT FOR PROTECTING AN OPTICAL FIBER COUPLER AND A METHOD OF MANUFACTURING THE SAME

Abstract: A protective arrangement for an optical fiber coupler (2) includes a substantially cross-sectionally V-shaped support element (11) which bounds an open channel (12) that receives a portion of the optical fiber coupler (2). The portion received in the open channel includes jacketed regions, continuing into bare regions (22) and a coupling region (23). Respective adhesive bodies (13) secure the jacketed regions of the optical fiber coupler (2) in the open channel (12) of the V-shaped support element (11). A strip-shaped support element (14) is connected by respective additional bodies (15) of adhesive to the bare regions of the fiber just outside the coupling region. The support elements (11, 14) are of a material having a coefficient of thermal expansion approx­ imating that of the material of the optical fiber coupler (2). A shrunk tubular shielding element (16) tightly surrounds the V-shaped support element (11) over most of its length and its open ends are closed by respective seals (18). Shrunk tubular bend limiters (17) surround the jacketed regions of the optical fiber coupler and pass through the respective seals (18). This sub-package (1) is so inserted into a receiving channel (31) of a housing member (3) that the open side of the open channel of the V-shaped support element (11) faces the bottom surface of the receiving channel (31). A body of encapsulating material (4) embeds the subpackage (1) and holds the same in position within the receiving channel (31).

Description: Arrangement for protecting an optical fiber coupler and a method of manufacturing the same The present invention relates to an arrangement for protecting an optical fiber coupler of an optical material and a method of manufacturing the same. Optical fiber couplers of various constructions are already known and in widespread use, especially in the telecommunications field. Generally speaking, such optical fiber couplers render it possible to interconnect individual optical fibers in such a manner that the modulated light. propagating through an input optical fiber leading to the optical fiber coupler continues to propagate through at least one output optical fiber leading from the optical fiber coupler after passing through the latter. In some of the conyentional optical fiber coupler constructions, at least two input optical fibers merge or are fused with one another at a coupling region of the optical fiber coupler so that the output light signal or each of such output light signals is a combination or function of the input light signals. The present invention is primarily, but not exclusively, concerned with optical fiber couplers of the latter type, that is, with optical fiber couplers in which mixing of the input light signals takes place Optical fiber couplers of the above-discussed type are very sensitive to environmental influences not only because they are made of an optical material, usually glass, which is very fragile, but aLso because the coupling region is proper and its vicinity are usually bare, that is, not provided with a jacket, so that environmental influences could affect the quality of the optical material of the optical fiber coupler and/or of the signals transmitted through the coupler, Lest the exposed or bare region of the optical fiber coupler is protected from environmental in influences. In view of the above, it has been already proposed to encase the optical fiber coupler in such a manner as to protect the exposed region from deleterious environmental influences. However, experience with conventional constructions of such coupler-protecting arrangements has shown that they leave much to be desired as far as the protecting function thereof is concerned, especially in a use where the optical fiber coupler and the protective arrangement therefor are often subjected to extremely high or extremely low temperatures and/or very high temperature variations in relatively short periods of time, and/or to vibrations or impacts of considerable magnitudes. Thus, it has been observed that the failure or breakage rate of optical fiber couplers encased in the conventional ways is very high, which presents a severe limitation to the use of conventionally encased optical fiber couplers in communication applications. It is an object of the present invention to so construct the protective arrangement of the type here under consideration as to reduce the possibility of damage to the optical fiber coupler to a minimum even under extreme conditions and to so design the protective arrangements of the above type as to be simple in construction, inexpensive to manufacture, easy to use, and reliable in operation nevertheless. A concomitant object of the present invention is to devise a method of manufacturing the optical fiber coupler protecting arrangement of the above-type in a simple and rather inexpensive way. In pursuance of this object which will become apparent hereafter, one feature of the present invention resides in an arrangement for protecting an optical fiber coupler of an optical material which can be damaged if exposed to environmental influences, this arrangement comprising'at least one elongated support element extending along the coupler, and means for attaching the coupler to the support at least at two locations spaced from one another longitudinally of the support element. Advantageously, the support element is of a material having a coefficient of thermal expansion close to that of the optical material of the coupler, especially a metallic material, such as an iron-nickel alloy. The support element advantageously has substantially through-shaped configuration so as to bound an open channel, so that at least that portion of the coupler which extends between the two locations is received in the open channel. It is especially advantageous when the arrangement further comprises means for encasing the support element and at least that portion of the coupler which is coextensive with the latter this encasing means advantageously including a rigid housing member bounding a receiving channel dimensioned to receive the support element and the aforementioned part of the coupler with a clearance, and a body of filling material substantially filling the clearance. The trough-shaped support element with the coupler therein may advantageously be surrounded by a shrunk tubular shieLding element. The method according the present invention of manufacturing a protecting arrangement for an optical fiber coupler of an optical material which can be damaged if exposed to environmental influences comprises the steps of providing a trough-shaped support element with an open channel; placing the coupler into the open channel; adhesively attaching the coupler to the support element in the open channel; surrounding the support element with a tubular shielding element of a shrinkable material; shrinking the shielding element around the trough-shaped support element to form a subassembly; inserting the subassembly with clearance into a receiving channel of a housing member; seating the open ends of the tubular shielding element around the coupler with respective seals which are so dimensioned as to simultaneously delimit a receiving space in the clearance between the shielding element and the housing member; substantially filling the receiving space with a body of hardenable material to embed the subassembly; and causing the hardenable material to harden. Above-mentioned and other features and objects of this invention will become more apparent by reference to the following description taken in conjunction with the accompanying drawing, in which: Fig. 1 is a bottom plan view of a subassembly of an optical fiber coupler with a V-shaped support element and an additional strip-shaped support element; Fig. 2 is a top plan view of a package including the subassembly of Fig. 1 received in a receiving channel of a housing member, prior to embedding; and Fig. 3 is a cross-sectional view taken along line III-III of Fig. 2 but subsequent to embedding. Referring now to the drawing in detail, and first to Fig. 1 thereof, it may be seen that the reference numeral 1 has been used to identify a protective arrangement or subassembly for an optical fiber coupler 2. The arrangement 1 includes, as one of its main components, a troughshaped support element 11 which is preferably V-shaped in cross section to bound a substantially cross-sectionally triangular open channel 12 receiving a portion of the optical fiber coupler 2. The optical fiber coupler 2 includes respective jacketed input and output portions 21 which are partially received in the open channel 12 of the support element 11. The optical fiber coupler 2 then continues in the axial direction of the open channel 12 by stripped or bare portions 22 which then taper toward and are joined to one another at a merger or coupling region 23. The optical fiber coupler 2 is held in position in the open channel 12 by two bodies 13 of an adhesive, advantageously a heat-cured epoxy adhesive, which are situated at two locations that are spaced from one another longitudinally-of the open channel 12 and each of which secures one of the jacketed portion 21 of the optical fiber coupler 2 to the V-shaped or trough-shaped support element 11. The support element 11 is made of material having a coefficient of thermal expansion close to that of the optical material of the optical fiber coupler 2. Various metallic material especially iron-nickel alloys, satisfy this condition. One metallic material which is especially suited for this purpose and which has been successfully tested is currently being marketed under the trademark Invar. This material is an iron-nickel aLloy containing about 64 percent of iron and 36 percent of nickel. However, other metallic materials, especially of the ironnickel alloy family, are contemplated for use to make the trough-shaped support element 11 therefrom so long as the coefficient of thermal expansion is close to if not identical to that of an optical material of the optical fiber coupler 2. It will be appreciated that it may be desirable if not necessary to use different metallic materials for trough-shaped support elements 11 used with optical fiber couplers 2 of drastically different thermal expansion coefficients but, since there is no requirement for the thermal expansion coefficients of the materials of the support element 11 of the optical fiber coupler to be exactly equal, there is a certain leeway in selecting the materials, in fact, the same material may be used for op tical fiber couplers 2 having thermal expansion coefficients within a relatively wide range. As also shown in Fig. 1, the arrangement 1 may further include a strip-shaped support element 14 which extends along the bare portions 22 and the coupling region 23 of the optical fiber coupler 2, being connected to the bare portions 22 at two zones spaced from one another in the axial direction and situated outside the coupling region 23 and between the locations 13. The connection of the stripshaped support element 14 to the bare portions 22 is accomplished by respective bodies of adhesive 15 situated at the respective zones. The adhesive may again be heatcurable epoxy and the material of the strip-shaped support element 14 has similar properties as the material of the trough-shaped support element 11 or may even be identical therewith. The strip-shaped support element 14 serves to reinforce the coupling region 23 of the optical fiber coupler 2 prior to and during the introduction of the optical fiber coupler 2 into the open channel 12 of the trough-shaped support element 11, and confines the coupling region 23 of the optical fiber coupler 2 between itself and the support element 11 upon assembly. However, the strip-shaped support element 14 is optional and may be omitted when the space available in the open channel 12 is sufficient for securing the bare fibers of the optical fiber coupler 2 directly to the trough-shaped support element 11. As a comparison of Figs. 1 and 3 will reveal, a tubular shielding element 16 surrounds the trough-shaped support element 11 over most if not all of the axial length of the latter. At least as applied to the trough-shaped support element 11, the tubular shielding element 16 has a non-circular cross section which, as may be seen in Fig. 3, conforms to the outline of the trough-shaped support element 11 except for a portion of the shielding element 16 which spans the open side of the open channel 12, that is, extends across the open side of the channel 12. It is currently preferred to make the shielding element 16 of a shrinkable material, and to shrink the same in place so as to obtain a tight contact between the external surfaces of the trough-shaped support element 11 and the internal surface of the shieLding element 16. It may also be seen in Fig. 1 that a region of each of the jacketed portions 21 of the optical fiber coupler 2 is surrounded, in each instance, by a tubular bend limiter 17. The bend limiter 17 is preferabLy aLso of a shrinkable material and is shrunk in place on the respective jacketed portion 21 of the optical fiber coupler 2. The respective bend limiter 17 is shown to extend from the interior of the tubular shielding element 16 to beyond the troughshaped support element 11. It reinforces the optical fiber coupler 2 in this area and limits the extent of bending of the optical fiber coupler 2. Since the shielding element 16 spans the open side of the channel 12, a gap exists between the shieLding element 16 and the bend limiter 17 at each of the ends of the shielding element 16. This gap is shown in Fig. 1 to be filled with a seal 18, especially by a body of an RTV sealent, which separates the interior of the shielding eLement 16 from its exterior. Thus, ambient air is prevented from entering the interior of the shielding element 16 and thus the bare fiber portions 22 and the coupling region 23 of the optical fiber couplers 2. If desired, either the shielding element 16 or the seals 18, or both, may be of an opaque material, so that even ambient light is prevented from reaching the bare optical fibers of the optical fiber coupler 2 therethrough. The arrangement as discussed so far already gives optical fiber couplers a measure of protection which may be sufficient for certain applications or uses of the optical fiber coupler 2. However, for more demanding applications, such as those encountered especially in the military use, an additional protection may be needed. Thus, as shown in Figs. 2 and 3, the above-discussed protective arrangement 1 assembled with the optical fiber coupler 2 is used as a sub-package which is inserted into a receiving channel 31 of a housing member 3. As may best be seen in Fig. 3, the housing 3 has two lateral portions 32 which are shown to be configurated as flanges. The lateral portions 32 are provided with holes 33 through which screws or similar fasteners may be passed to mount the housing 3 on a supporting structure. However, it will be appreciated that the lateral portions 32 could also extend over the entire height of the housing 3 for additional reinforcement purposes. As illustrated in Fig. 3, the housing 3 has two lateral walls 34 and a bottom or interconnecting wall 35 extending between and merging with the lateral wall 34. The walls 34 and 35 together bound the receiving channel 31. Fig. 3 also shows that the trough-shaped or V-shaped support element 11 is so received in the receiving channel 31 that the open side of the channel 12 thereof faces downwardly, that is, toward the interconnecting waLL 35. Of course, the portion of the shielding eLement 16 which spans the open side of the open channel 12 is interposed between the support element 11 and the bottom wall 35 of the housing member 3. Then, the entire subpackage is encased in a body 4 of an encapsulant especially of a resilient, opaque and encapsulant. The body 4 may fiil the entire remainder of the receiving channel 31 Left after the above-mentioned sub-package has been introduced into the receiving channel 31, in which case the seals 18 prevent the encapsulating material from entering the interior of the tubular shieLding element 16. Alternatively, as shown in Fig. 2, the seals 18 may have portions which are so dimensioned as to sealingly contact the surfaces bounding the receiving channel 31, thus axially delimiting a receiving space substantially coextensive with the shielding element 16 in the receiving channel 31. In this case, only the aforementioned receiving space need be filLed with the encapsulant. Having so described the construction of the protecting arrangement or package for the optical fiber coupler 2, the currently preferred method of manufacturing the same will now be briefly discussed. If the strip-shaped support element 14 is to be used, it is attached to the bare portion 22 of the optical fiber coupler 2 by the respective adhesive bodies 15 situated just outside the tapering or coupling region 23 of the optical fiber coupler 2 first, followed by hardening of the bodies 15 of adhesive. This hardening may be caused or accelerated by applying heat to the adhesive bodies 15 or to the strip-shaped support element 14, or both, such as by using a heat gun or a heated fixture. Then, the resulting article is introduced into the open channel 12 of the trough-shaped support element 11 and is secured therein by the respective bodies 13 of adhesive. This adhesive may again be cured, or its curing may be accelerated, by applying heat to the zones at which the bodies 13 are situated, by a heat gun or a heated structure. Once this is accomplished, the shielding element 16 of a shrinkable material is slid over the troughshaped support element 11 and is shrunk in the desired position. This is followed by situating the bent limiters 17 at the desired locations, and by causing the same to shrink to tightly embrace the jacketed portions 21 of the optical fiber coupler 2. This is followed by filling the gaps between the shielding element 16 and the bent limiters 17 by the seals 18. The resulting sub-assembly or sub-package 1 is then introduced into the receiving channel 31 of the housing member 3 in the above-mentioned orientation, and is properly aligned therein. Then, a body of the encapsulate, which is then in its flowable state, is poured into the receiving channel 31 or into the receiving space until it fills the receiving channel 31 or the receiving space. Then, the body 4 is permitted or caused to cure within the confines of the receiving channel 31. This completes the manufacture of the heavy-duty construction of the optical fiber coupler/protective arrangement article, which is then ready for storage, transportation and/or use.

Claims: CLaims 1. Arrangement for protecting an optical fiber coupLer of an optical material c h a r a c t e r i z e d in that at least one elongated support element (11) is extending along the coupler (2), and that means (13) are provided for attaching the coupler (2) to said support element (11) at Least at two locations spaced from one another Longitudinally of said support element (11). 2. An arrangement as defined in claim 1, characterized in that the support eLement (11) is of a metallic material having a coefficient of thermal expansion close to ±hat of the optical material of the coupler (2). 3. An arrangement as defined in claim 1, characterized in that the support element (11) has a substantially trough-shaped configuration with a substantially V-shaped crops section so as to bound an open channel (12); and wherein at least that portion of the coupler (2) which extends between said two locations is received in said open channel. 4. An arrangement as defined in claim 3, characterized in that there is provided further a tubular shielding element (16) surrounding at least that part of said trough-shaped support element (11) which extends between said two locations. 5. An arrangement as defined in claim 4, characterized in that the shielding element (16) is in tight contact with the exterior of said part of said trough-shaped support element (11) and extends across said open channel (12) and is of a shrinkable material and is shrunk in place to obtain said tight contact and has two longitudinally spaced end portions; and further comprising means for sealingly closing said end portions, including seals (18) extending at least inwardly from said end portions. 6. An arrangement as defined in claim 5, characterized in that there is provided further a pair of tubular end limiters (17) each snugly surrounding the coupler (2) at the region of one of said end portions of said tubular shielding element (16) and wherein each of said bend limiters (17) is of a shrinkable material and is shrunk in place on the coupler (2) and wherein said seals (18) sealingly engage said bend limiters (17). 7. An arrangement as defined in claim 3, characterized in that there is provided further an additional support element (14) of a strip-shaped configuration extending along the coupler (2) and having a shorter length than said support element (11), and means for securing said additional support element to the coupler (2) at least at two zones spaced a smaller distance from one another than said two locations and wherein said zones are situated between said locations upon assembly and wherein said securing means includes respective bodies (15) of an adhesive substance at said zones. 8. An arrangement as defined in claim 1, characterized in that the attaching means includes respective bodies (15) of an adhesive at said Locations. 9. An arrangement as defined in claim 1, characterized in that further means are provided for encasing said support element (11) and at Least that portion of the coupler (2) which is coextensive with the latter, incLuding a rigid housing member (3) bounding a receiving channel (31) dimensioned to receive said support element and said part of the coupler (2) with a clearance, and a body (4) of filling material substantially filling said cLearance. 10. An arrangement as defined in claim 9, characterized in that the housing member (3) includes two lateral walls (34) and an interconnecting walL (35) interconnecting said lateral walls and bounding said receiving channel (31) therewith; and wherein said trough-shaped support member (11) is so oriented in said receiving channel (31) that the open side of said open channel (12) faces said interconnecting wall (35). 11. An arrangement as defined in claim 10, characterized in that the seaLs (18) arranged- at and closing the open end portions of the shielding element have outer dimensions substantially corresponding to those of said receiving channel (31) to be fittingly received therein and to de limit a receiving space for said body (4) of filling material. 12. A method of manufacturing a protecting arrangement for an optical fiber coupler of an optical material comprising the steps of: providing a trough-shaped element with an open channel; placing the coupler into the open channel; adhesively attaching the coupler to the support element in the open channel; surrounding the support element with a tubular shielding element of a shrinkable material; shrinking the shielding element around said trough-shaped element to form a subassembly; inserting the subassembly with clearance into a receiving channel of a housing member; sealing the open ends of the tubular shielding element around the coupler with respective seals which are so dimensioned as to simultaneously delimit a receiving space in the clearance between the shielding element and the housing member; substantially filling the receiving space with a body of a hardenable material to embed the subassembly; and causing the hardenable material to harden.

Inventors: HOFFMAN, ARTHUR JAMES
Applicants: ALCATEL N.V.
Application year: 1983
Main classification: G02B6
IPC codes: G02B6