Method of making fiber optic couplers

Abstract: A fiber optic coupler is formed by providing a glass tube (10) having a longitudinal aperture (11) extending therethrough. Protective coating (21) is removed from a region of a first optical fiber (17) intermediate the ends thereof. Protective coating (22) is removed from an end region of at least one other optical fiber (18). The coated portion of the first fiber (17) is threaded through the tube (10) until the uncoated region thereof is near the tube end. The uncoated region of the second fiber (18) is placed adjacent that of the first fiber, and both uncoated regions are simultaneously fed into the tube aperture. After the threading operation has continued until the uncoated regions extend through the midregion (27) of the tube (11), the midregion is heated to collapse it about the fibers, and the central portion of the midregion is drawn to reduce the diameter thereof over a predetermined length.

Description: This application is related to the following European Patent Applications: EP-A-302745 entitled "Method of Making an Economical Fiber Coupler"; EP-A-352957 entitled "Method of Reproducibly Making Fiber Optic Coupler"; and Application No. 90306147.1 (EP 407 034) entitled "Method of Making Optical Devices". The present invention relates to a method of making fiber optic couplers and is especially applicable to the fabrication of 1xN couplers which couple light from one optical fiber to N optical fibers, wherein N is a number equal to 2 or more. In addition to performing the coupling function, such devices can also be designed to perform such functions as wavelength division multiplexing, filtering and the like. In couplers wherein N is greater than two, a usual requirement is that the power be equally coupled from the input fiber to the N output fibers. Methods of making multimode 1xN couplers are disclosed In US-A-4083625 (Hudson) and in GB-A-2023874. Both of these documents teach methods that initially require fusing together and stretching the end portions of first and second optical fibers. In accordance with the Hudson patent, the common endface of the fused first and second fibers is fused to the endface of a third optical fiber. The British document teaches that a spheroidal lens is formed on the common end of the tapered first and second fibers, and a third fiber is positioned such that light radiating therefrom is coupled by the lens to the first and second fibers. These couplers are not suitable for single-mode fibers. JP-A-63-217314 discloses a method of making a lxN fiber optic coupler. A plurality of optical fibers are disposed in a tube such that at least a part of each fiber extends into the bore of the tube. The middle part of the tube is drawn by heating. This causes the entire tube to assume a tapered shape, the central portion of the tube having the smallest diameter. Since the fibers are not provided with a protective coating material, the diameter of the tube bore can be made just large enough to accept the assembly of the six fibers surrounding a central fiber. Single-mode couplers have been made by forming NxN couplers and severing and/or terminating N-1 fibers at one end of the device. For example, an NxN single-mode optical fiber coupler can be formed in accordance with the teachings of European patent application No. 0302745, published 08 Feb 89. A plurality of suitable prepared glass fibers, each having a core and cladding, are disposed within the longitudinal aperture of a glass capillary tube. Each fiber extends beyond at least one end of the tube to form a connection pigtail. The pigtails are provided with the same type and diameter of plastic coating as the optical fibers of the system in which the device is intended to be used so that the device can be easily integrated into the system. The midregion of the tube is heated and collapsed about the fibers, and the central portion of the collapsed midregion is stretched to reduce the diameter thereof. To form a 1x2 coupler, for example, two fibers are employed to initially form a 2x2 coupler, and one of the coupler pigtails or legs is terminated. In this type of coupler, the terminated leg is located external to the glass tube. A requirement for certain coupler applications is that the terminated leg be such that the back reflection of optical power therefrom is substantially reduced. A common specification for such applications is that the reflected power be no more than -50 dB. The preparation of the optical fibers for the above-described method has involved removing the coating from that portion of the fiber which is positioned at the midregion of the tube. The coated portions of the fibers are pulled through the tube aperture in order to position the uncoated region in the center of the tube prior to the tube collapse step. The coated portions of each fiber extend into the ends of the tube aperture to hold the fibers in proper alignment while the tube is collapsed thereon. The aperture must therefore be large enough to accept the coated portions of the fibers. When the aperture diameter is relatively large, whereby the tube must undergo an inordinate amount of collapse prior to the time that it engages the fibers therein, bubbles are more likely to form in the coupling region, and/or glass is more likely to flow between the fibers during the tube collapse step. These effects adversely affect optical characteristics such as attenuation and coupling ratio. When N is large, it becomes more difficult to make 1xN couplers by severing and/or terminating pigtails extending from an NxN coupler. In such a coupler the input fiber must be centrally located with respect to the output fibers in order to obtain the best distribution of optical power to all output ports. Each of the N input ports of the initially formed NxN coupler would have to be measured in order to determine the centrally located port. A 16x16 coupler would require 256 measurements. It is an object of the present invention to provide a method that overcomes the disadvantages of the prior art. Another object is to provide a method of making fiber optic couplers wherein capillary tube hole size is maintained sufficiently small that the tube collapse step is enhanced. A further object is to provide a method of making optical couplers, the optical properties of which closely conform to predetermined values. Another object is to provide a method of making 1xN fiber optic couplers wherein no external end terminations are needed for preventing the reflection of optical power from the terminated endface back into the fiber. One aspect of the invention concerns a method as defined in claim 1 The uncoated section of the "second fibre" referred to in claim 1 may have a rounded end. The end region of the uncoated section may be tapered to a smaller diameter than the remainder of the uncoated section. The diameter of the spherically-shaped end is preferably no greater than the diameter of the non-tapered diameter of the fiber, whereby the diameter of the tube bore can be made relatively small, thereby enhancing the step of collapsing the tube. The spherically-shaped end may be formed by removing coating from the end of a coated fiber to form an uncoated end region, heating the uncoated end region remote from the end thereof and pulling on opposite sides of the heated region to sever the end. This process leaves on the fiber an uncoated tapered end region. The end of the tapered region is heated to lower the viscosity of the material thereof by an amount sufficient to cause the material to recede back along the fiber and form a rounded endface. The reflectance of the rounded endface can be monitored during the formation thereof. If such monitoring is performed, the step of heating the end of the tapered region is continued until the reflectance is reduced to a predetermined value. The method may comprise positioning the uncoated section of the additional fiber adjacent the uncoated section of the first fiber, and simultaneously moving the uncoated sections into the tube. To facilitate this step, the uncoated section of the second fiber can be attached to the first fiber. The point of attachment may be the coating or the uncoated section of the first fiber. In the method prior to collapsing the tube, a quantity of glue can be deposited at both ends of the tube aperture to secure to the tube those portions of the first fiber and the plurality of fibers which extend from the ends of the tube. Any part of an uncoated portion of the plurality of fibers which extends beyond the glue is preferably severed. It is convenient to support the tube in a vertical orientation. The first fiber is threaded through the aperture until the uncoated section thereof lies below the tube, and the top portion of the first fiber which extends from the top of the tube is restrained. The uncoated section of the second fiber is positioned adjacent the uncoated section of the first fiber. The top portion of the first fiber is pulled upwardly to position the uncoated section thereof in the aperture. The uncoated section of the at least one additional fiber is simultaneously moved into the aperture. Another aspect of the invention concerns the resultant coupler as defined in claim 7. The end of the second fiber which terminates within the second passageway can have a spherically-shaped end, the diameter of which is smaller than the diameter of that section of the second fiber that is located in the first aperture. The spherically-shaped end is capable of reflecting back into - the second fiber less than -50 dB of the power that propagates through the fiber and impinges thereon. Fig. 1 is a cross-sectional view of a capillary tube after optical fibers have been inserted therein. Fig. 2 is an oblique view of an apparatus for forming an antireflection termination on the end of an optical fiber. Fig. 3 is a block diagram illustration of a system for measuring the back-reflectance of an optical fiber. Figs. 4 and 5 are schematic illustrations of two steps during the operation of the apparatus of Fig. 2. Fig. 6 is a schematic illustration of an apparatus for collapsing a capillary tube and drawing the midregion thereof. Fig. 7 is a partial cross-sectional view illustrating the collapse of the glass tube around the fibers to form a solid midregion. Fig. 8 is a cross-sectional view through the solid midregion of Fig. 7 along lines 8-8. Fig. 9 is a partial cross-sectional illustration of a fiber optic coupler after it has been drawn down and sealed at its ends. Figs. 10 and 11 are schematic illustrations of aperture cross-sections having fibers disposed therein. The drawings are not intended to indicate scale or relative proportions of the elements shown therein. A first embodiment pertains to an improved method of making 1x2 fiber optic couplers. This method employs a tube 10 (Fig. 1) having a longitudinal bore or aperture 11. Tapered apertures 12 and 13 form funnel-like entrances to aperture 11 at end surfaces 14 and 15, respectively. The softening point temperature of tube 10 should be lower than that of the fibers that are to be inserted therein. Suitable tube compositions are SiO 2 doped with 1 to 25 wt. % B 2 O 3 and SiO 2 doped with 0.1 to approximately 2.5 wt. % fluorine. Glasses comprising silica and combinations of these dopants can also be employed. Tube 10 can be formed by depositing glass particles on a cylindrical mandrel to form a porous, cylindrically-shaped preform. The mandrel is removed, and the porous preform is dried and consolidated to form a tubular glass body which is heated and redrawn to reduce its diameter. Apertures of non-circular cross-section can be formed in the tube by shrinking the tube onto a carbon mandrel of desired cross-section and then burning out the mandrel and stretching the tube to decrease its diameter. A short section of tube having tapered apertures 12 and 13 can be formed by attaching a capillary tube to a source of air pressure, and while rotating the tube, directing a flame onto the tube at spaced intervals. The pressure within the tube forms a bubble at each region softened by the flame. The tube is scored and severed at the center of each bubble. Two lengths 17 and 18 of coated optical fiber are severed from a reel of fiber. Coated fibers 17 and 18 comprise glass fibers 19 and 20, respectively, each comprising a core and a cladding and each having a protective coating 21 and 22, respectively. A portion of the coating intermediate the ends of coated fiber 17 is removed for a distance slightly longer than the length of aperture 11 but shorter than the length of tube 10. The apparatus shown in Fig. 2 can be employed to provide a low reflectance termination which is required for many coupler applications. Table 29 is slidable in the x direction along grooves 28a of base 28. An oxygen-acetylene torch 24 is mounted on base member 28 so that it can be moved in the y and z directions. The position of torch 24 is initially adjusted in the z direction so nozzle 24′ lies approximately in the plane of the surface of table 29. Two closely spaced guides 30 are located at one end of table 29 in alignment with a fiber retaining groove (not shown). A fiber is held in the groove by retainer disk 36. Microscope 26 is mounted on table 29 in such a location that the end of a fiber extending beyond table 29 appears in its field of view. The coating is removed from the end of coated fiber 18. An oxygen-acetylene flame is directed at the uncoated fiber a short distance from the end thereof, and the end of the fiber is pulled until it becomes severed from the remainder of the fiber. As shown in Fig. 4, the fiber now has a tapered end. The end of coated fiber 20 remote from the tapered end is connected to the apparatus of Fig. 3 to monitor the reflectance from the tapered end. The system of Fig. 3 comprises a 2x2 3 dB coupler having ports 1-4. A laser is connected to port 1, and an optical power meter is connected to port 2. The end of the optical fiber that comprises port 3 is cleaved, and that end is immersed in a tube of index matching gel to prevent the reflection of light from the immersed end back through the coupler to the power meter. The end of fiber 20 remote from the tapered end is fusion spliced to port 4. Laser light which reflects from the tapered end of fiber 20 (and from the rounded end formed by the Fig. 2 apparatus) passes through the coupler to the power meter. Fiber 20 is placed between guides 30 such that it lies in the groove in the surface of table 29 with its tapered end extending beyond the table toward nozzle 24′. The end of the fiber is positioned in the center of the microscope field. With torch 24 turned off and table 29 moved to the left of base 28 (as viewed in Fig. 2), the position of torch 24 is adjusted in the y direction such that the end of the fiber is adjacent nozzle 24′ (Fig. 4). Table 29 is moved to the right, and the torch is ignited. Only the bright, central portion 23 of the flame is illustrated in Figs. 4 and 5. Table 29 is moved slowly to the left, whereby the tapered tip of fiber 20 is heated by the flame. The tapered end is provided with a low reflectance termination by heating it to lower the viscosity of the material thereof by an amount sufficient to cause the material to recede back along the fiber and form a rounded endface 25 (Fig. 5), the final diameter of which is about equal to or slightly smaller than the original uncoated fiber diameter. The heating is continued until the power of the laser light that reflects from the rounded end and propagates back through the fiber toward the opposite end is less than a predetermined value. A current specification for the reflected power is -50 dB. Continued heating of the rounded endface would cause the glass from the tapered end to continue to recede, thereby increasing the diameter of the rounded end with essentially no improvement in reflection reduction properties. If the diameter of the rounded end were to become larger than that of the fiber, the tube aperture 11 would have to be made large enough to accommodate it. Therefore, it is preferred that the step of heating the tapered end be terminated before the diameter of the rounded endface becomes larger than the initial diameter of the uncoated fiber. If the uncoated portion of fiber 20 is too short after the antireflection termination has been formed, an additional length of coating is removed, whereby the total uncoated section of optical fiber 20 is sufficiently long that it extends beyond the tube midregion 27 when the end of coating 22 is situated in tapered aperture 13. After the fiber insertion process, fiber end 25 preferably does not extend beyond tube end 14; it may be located within tapered aperture 12 or in the end of longitudinal aperture 11. The fibers are wiped to eliminate residual material. A small amount of ethyl alcohol may be squirted into the tube to temporarily lubricate the fibers during insertion thereof; it then readily evaporates. Coated fiber 17 is inserted through aperture 11 until the uncoated section thereof is situated just beyond tube end 15. The uncoated portion of coated fiber 18 is held adjacent the uncoated portion of coated fiber 17, and both coated fibers are moved together toward tube end 14 until the coating end regions, which are adjacent one another, become wedged in tapered aperture 13. The uncoated portion of coated fiber 17 is then disposed intermediate end surfaces 14 and 15, the uncoated portion of coated fiber 17 preferably being centered within aperture 11. End 25 of fiber 18 is located between midregion 27 and end 14 of tube 10. The stripped portion of fiber 17 could initially be centered in aperture 11, and the stripped end portion of fiber 18 could thereafter be inserted into the aperture. However, the fiber insertion process is facilitated by simultaneously inserting both stripped portions. Apparatus for collapsing and stretching the resultant preform 31 is shown in Fig. 6. Chucks 32 and 33, which secure preform 31 in this apparatus, are mounted on motor controlled stages 45 and 46, respectively, which are preferably controlled by a computer. Heat shield 35 protects the apparatus located above ring burner 34. Preform 31 is inserted through ring burner 34, is clamped to the draw chucks, and vacuum attachments 41 and 41′ are attached to the ends thereof. Vacuum attachment 41, which is shown in cross-section in Fig. 1, may comprise a tube 40, a collar 39 threaded thereon, and an O-ring 38 disposed between the collar and tube. After vacuum attachment 41 is slid over the end of tube 10, collar 39 is tightened, thereby compressing O-ring 38 against the tube. Vacuum line 42 is connected to tube 40. One end of a length of thin rubber tubing 43 is attached to that end of vacuum attachment 41 that is opposite preform 31; the remaining end of the tubing extends between clamp jaws 44. Upper vacuum attachment 41′ is similarly associated with line 42′, tubing 43′ and clamp jaws 44′. The coated portions of the fibers extend from tubing 43 and 43′. Tube 10 can be secured by chucks 32 and 33 prior to the fiber insertion step. While tube 10 is supported vertically by the chucks, the fibers are inserted as described above. The fibers extending from both ends of the tube are threaded through their respective vacuum apparatus, and vacuum attachments 41 and 41′ are connected to the tube. Vacuum is applied to the lower portion of coupler preform 31 by clamping jaws 44 on tubing 43 while the upper vacuum attachment is vented to air or connected to a source of inert gas or a liquid cleaning agent. This washes from aperture 11 any loose debris which has accumulated therein during the fiber insertion step. Jaws 44′ are then clamped against tubing 43′ to apply vacuum to the upper portion of preform 31. The flame from ring burner 34 heats tube 10 for a short period of time, typically about 25 seconds, to increase the temperature of midregion 27 of the tube to the softening temperature thereof. With the assistance of the differential pressure on the tube, the matrix glass collapses onto fibers 19 and 20 and urges them into mutual contact. The tube matrix glass surrounds the fibers and fills the aperture to form a solid structure as shown in Figs. 7 and 8. Midregion 27, the central portion of which forms the coupling region of the resultant coupler, becomes a solid region wherein substantially the entire lengths of fibers 19 and 20 are in mutual contact. The longitudinal length of the collapsed region depends upon the temperature and time duration of the flame, the thermal conductivity of the glass tube, and the amount of vacuum applied. After the tube cools, the flame is reignited, and the center of the collapsed region is reheated to the softening point of the materials thereof. The flame duration for the stretch process, which depends upon the desired coupler characteristics, is usually between 10 and 20 seconds. The shorter heating period for the stretch step results in a stretched region that is shorter than the collapsed region. Stretching only the central portion of the collapsed midregion ensures that the coupling region of the fibers will be embedded in the matrix glass of the capillary tube. During this reheating step, the fibers are also heated since they are completely surrounded by the matrix glass of the capillary tube and are therefore in thermal contact therewith. After the collapsed tube is reheated, the flame is extinguished and stages 45 and 46 pull in opposite directions until the coupler length has been increased by a predetermined amount to bring the fiber cores closer together along a distance sufficient to accomplish a predetermined type of coupling. The diameter of midregion 27 is reduced as illustrated by region 51 of Fig. 9. The diameter of drawn down region 51 depends upon various fiber and operational parameters. The ratio of the drawn down diameter of region 51 to the starting diameter of midregion 27 (the draw down ratio) is determined by the optical characteristics of the particular device being made. It is well known that such draw down ratios are a function of the ratio of the signal split between the fibers, the refractive index difference between the tube and the fiber cladding, the outside diameter of the fiber cladding, the diameter of the fiber core, signal operating wavelength, cutoff wavelength, the tolerable excess loss, and the like. A preferred range of draw down ratios is between about 1/2 to 1/20; however, couplers can be made having draw down ratios outside this range. The amount of stretching to which the coupler preform must be subjected to achieve a given type of coupler is initially determined by injecting light energy into the input fiber of a coupler preform and monitoring the output power at the output fibers during the stretch operation. The predetermined ratio of the dynamic output powers from the two fibers can be used as an interrupt to cause stages 45 and 46 to stop pulling the sample. After having determined the proper stretching distance to achieve predetermined coupling characteristics, the apparatus can be programmed to move the stages that proper stretching distance during the fabrication of subsequent couplers that are to have said predetermined characteristics. It is conventional practice to monitor output signals to control process steps in the manufacture of optical devices as evidenced by U.S. patents Nos. 4,392,712 and 4,726,643, U.K. Patent Application No. GB 2,183,866 A and International Publication No. WO 84/04822. Furthermore, computers are often employed to in feedback systems which automatically perform such monitor and control functions. A suitably programmed PDP 11-73 micro-computer can be utilized to perform these functions. The timing sequences that have been used in the fabrication of a particular type of coupler can be entered in a separate multiple command file that the computer recalls at run-time. The collapse and stretch steps that are required to make that particular coupler can be executed in succession by the computer on each coupler preform to reproducibly manufacture couplers. The process parameters that can be controlled by the computer to ensure coupler reproducibility are heating times and temperatures, flow rates of gases, and the rate at which the stages pull and stretch the coupler preform. The coupling characteristics of a coupler change as a newly formed coupler cools down. If the feedback system stops the stretching operation when 50% of the input power is coupled to each output fiber at 1300 nm, the coupling ratio at 1300 nm will not be 50/50 after the coupler cools down. The coupler is therefore monitored at a wavelength that is longer than the desired operating wavelength. If, for example, the output signals are split 50/50 at some wavelength such as 1400 nm at the end of the stretching operation when the coupler is still hot, a 50/50 split may be obtained at a desired operating wavelength such as 1300 nm after the coupler cools to room temperature. A wavelength of 1400 nm would therefore be employed to monitor that coupler output during the stretching operation. The vacuum lines are removed from the resultant coupler, and quantities 48 and 49 of glue are applied to the ends of the capillary tube (Fig. 9). Heat (arrow H) can be applied locally to the uncollapsed regions of the coupler to drive air from the aperture. The heat source is removed, and glue is drawn into the aperture and then cured. Glue 48 and 49 increases the pull strength of the fiber pigtails and produces a hermetic seal. The resultant fiber optic coupler 50 of Fig. 9 functions to couple a signal propagating in the sole optical fiber at end 14 to the two optical fibers extending from end 15. The coupler is then removed from the draw apparatus and can be packaged if additional stiffness is desired. Various modifications can be made to the above-described embodiment. Midregion 27 could be heated by means of a conventional single-flame burner during the tube collapse and stretch steps, in which case the capillary tube is preferably rotated with respect to the flame to provide uniform heating. The burner may traverse midregion 27 during the tube collapse step and/or the stretch step. During the tube collapse step, the vacuum source could be attached to only one tube end, in which case a traversing burner should traverse the tube toward the evacuated end of the tube. During the step of drawing the preform midregion, stage 45 could be moved at a different velocity than stage 46 and in the same direction as stage 46. Furthermore, tube 10 can be disposed in any orientation including vertical and horizontal during the tube collapse and/or drawing operations. If the collapse and stretch operations are performed in the same apparatus, it is preferred that tube 10 be allowed to cool prior to being reheated for the stretch step. This temporal separation of the two steps results in better process control and therefore better reproducibility. Couplers can also be made by an alternative embodiment wherein the steps of collapsing the tube onto the fibers and drawing or stretching the midregion of the tube are performed in a single heating operation. However, this modified embodiment can result in a reduction in hermeticity, and it can adversely affect manufacturing reproducibility. Heretofore, the size of the tube aperture has been dictated by the diameter of the coating, since the fiber coating extended through the tapered apertures at both ends of the coupler and extended a short distance into the central aperture 53 as shown in Fig. 10. In that prior method, the tube aperture was preferably shaped like a diamond or the like so that the coated fibers would be properly positioned by the aperture. Coatings 54 and 55 fit snugly into aperture 53; optical fibers 56 and 57 were therefore held in proper alignment at both ends of the tube. Since the aperture cross-section was sufficiently large to accommodate the fiber coating, the fibers were spaced from the aperture walls, and they were separated from each other by a distance, d, which is equal to twice the coating thickness. Following is the sequence of events that is believed to occur during the collapse step, reference being made to the schematic illustration in Fig. 10. As the aperture cross-sectional dimensions decrease in size during the tube collapse step, the flattened wall surfaces of the aperture eventually come into contact with the fibers. As the aperture undergoes further collapse, the fibers are urged toward each other until mutual contact is achieved. Since the fibers are initially separated by the distance d and since aperture 53 must undergo a considerable amount of collapse prior to the time that it contacts the fibers, the step of collapsing the tube onto the fibers may occur with less than optimal results, i.e. bubbles may form adjacent the fibers, or glass from the tube wall may enter the region between the fibers. The occurrence of these adverse effects can increase device loss and adversely affect process repeatability. In accordance with the present invention, the tube collapse step is enhanced by employing a capillary tube having an aperture of reduced cross-sectional size. This improvement is made possible by that feature of the present method whereby the coated portion of only one fiber is passed through aperture 11, the remaining coated fiber or fibers being stripped at the ends thereof, and the stripped ends being inserted in the aperture in such a manner that they do not occupy any portion of the aperture that is occupied by coated fiber. To illustrate the improvement of the invention, reference is made to Fig. 11. The absence of coatings in aperture 11 enables that aperture to be smaller in cross-section than aperture 53. Since the walls of aperture 11 undergo less inward movement before total collapse is achieved, and since fibers 19 and 20 must be moved a shorter distance to achieve mutual contact, the tube collapse step is more likely to be accomplished without matrix glass from the tube flowing between the fibers and without the deviation of the fibers from a linear path. Furthermore, because of the enhanced tube collapse step, the collapsed tube midregion is more likely to be free from air lines, bubbles, or the like. The process of the present invention should therefore more consistently produce couplers having low loss and predetermined coupling ratio. In addition, the use of preterminated fiber 20 allows the terminated end 25 to be located within glass tube 25. This eliminates the need to sever and terminate a leg after the coupler has been formed.

Claims: A method of making a fiber optic coupler by disposing two optical fibers (17, 18) such that at least a part of each fiber extends into the continuous bore (11) of a glass tube (10), at least that part of each fiber that is located in the tube midregion (27) having no coating thereon, and lengthwise stretching the central portion of said midregion, the method being characterized in that said tube bore initially includes a constant diameter region that extends through said tube midregion and a tapered region (12, 13) between each end of the tube and the constant diameter region, and in that the step of disposing comprises providing a first optical fiber (17) having a protective coating thereon except for an uncoated section remote from the ends thereof, providing a second optical fiber (18) having a protective coating thereon except for an uncoated section at one end thereof, and inserting the uncoated section of said first fiber into said tube bore either prior to or simultaneously with the step of inserting the uncoated section of said second fiber into said tube bore, the end of the uncoated portion of said second fiber terminating between said midregion and the end of said tube, the step of inserting the uncoated section of said first fiber into said tube bore continuing until the coated portions of said first and second fibers are located outside said constant diameter portion of said bore, and in that the tube midregion is heated and collapsed onto the fibers prior to the step of stretching the central portion of the tube midregion, and wherein the diameter of said constant diameter region is smaller than the sum of the diameters of a coated section of fiber and an uncoated section of fiber. A method in accordance with claim 1 wherein the step of providing a second optical fiber (18) comprises providing a fiber having an uncoated section (20) at one end thereof, said uncoated section having a rounded end (25). A method in accordance with claim 1 wherein the step of providing a second optical fiber (18) comprises providing a fiber having an uncoated section (20) at one end thereof, the end region of said uncoated section being tapered to a smaller diameter than the remainder of said uncoated section, said second fiber having a relatively enlarged spherically-shaped end (25), the diameter of which is no greater than the diameter of the non-tapered diameter of said fiber, whereby the diameter of the tube bore can be made relatively small, thereby enhancing said step of collapsing said tube. A method in accordance with claim 1 wherein the step of providing a second optical fiber comprises removing coating from the end of a coated fiber (18) to form an uncoated end region (20), heating said uncoated end region remote from the end thereof and pulling the fiber on opposite sides of the heated region to sever the end of said uncoated end region, thereby leaving on said second optical fiber an uncoated tapered end region, and subsequently heating the end of said tapered region to lower the viscosity of the material thereof by an amount sufficient to cause the material to recede back along the fiber and form a rounded endface (25). A method in accordance with claim 4 wherein the step of providing a second optical fiber further comprises monitoring the reflectance of said rounded endface (25) and continuing the step of heating the end of said tapered region until said reflectance is reduced to a predetermined value. A method in accordance with claim 1 wherein the step of positioning comprises supporting said tube (10) in a vertical orientation, threading said first fiber (17) through said aperture until the uncoated section (19) thereof lies below said tube, restraining the top portion of said first fiber which extends from the top of said tube, positioning the uncoated section (20) of said second fiber (18) adjacent the uncoated section (19) of said first fiber, pulling said top portion of said first fiber to position the uncoated section thereof in said aperture (11), and simultaneously moving said uncoated section (20) of said second fiber into said tube. A fiber optic coupler comprising an elongated glass body (10) having a solid midregion and first and second opposite end portions which respectively extend from said midregion to the first and second ends (14, 15) of said body, first and second continuous longitudinal passages respectively extending from said first and second ends of said body to the midregion thereof, said passages having a constant diameter region adjacent said midregion and a tapered region adjacent said tube ends, a first glass optical fiber (17) having a core and cladding, said first fiber extending through said body and beyond the first and second ends thereof, those portions of said first fiber extending from said body having protective coating thereon, the protective coating of said first fiber terminating within said tapered regions of said passages, a second glass optical fiber (18) having a core and cladding, one end of said second fiber extending beyond the first end of said body, the second end of said second fiber terminating within said second end portion of said body between said midregion and the end of said body, that portion of said second fiber within the solid mid region and second end portion of said body being uncoated, the central portion of said midregion having a diameter smaller than the diameter of the remainder of said glass body, the cores of said optical fibers being closer together in the central portion of said midregion than in the remainder of said glass body so that optical signals can be coupled from the core of one of said fibers to the core of another of said fibers, the diameter of said constant diameter regions being smaller than the sum of the diameters of a coated section of fiber and an uncoated section of fiber, and means (48, 49) in said first and second passages for sealing to said body any fibers extending therefrom. A fiber optic coupler in accordance with claim 7 wherein the second end (25) of said second fiber terminates within said second passage. A fiber optic coupler in accordance with claim 8 wherein the end of said second fiber (18) which terminates within said second passage has a spherically-shaped end (25), said spherically-shaped end having a diameter smaller than the diameter of that section of said second fiber that is located in said first passage, said spherically-shaped end being capable of reflecting back into said second fiber less than -50 dB of the power that propagates through said fiber and impinges upon said spherically-shaped end.

Inventors: BERKEY GEORGE EDWARD, KROWIAK MARK THOMAS, SAUNDERS DANIEL PAUL, BERKEY, GEORGE EDWARD, KROWIAK, MARK THOMAS, SAUNDERS, DANIEL PAUL
Applicants: CORNING INC, CORNING INCORPORATED
Application year: 1990
Main classification: G02B6
IPC codes: C03B23, G02B6