US20030091296A1 - Cold welding process for fiber optic/ferrule attachment - Google Patents
Cold welding process for fiber optic/ferrule attachment Download PDFInfo
- Publication number
- US20030091296A1 US20030091296A1 US10/001,539 US153901A US2003091296A1 US 20030091296 A1 US20030091296 A1 US 20030091296A1 US 153901 A US153901 A US 153901A US 2003091296 A1 US2003091296 A1 US 2003091296A1
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- US
- United States
- Prior art keywords
- ferrule
- fiber
- bore
- cable
- sleeve
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
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Classifications
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/24—Coupling light guides
- G02B6/36—Mechanical coupling means
- G02B6/38—Mechanical coupling means having fibre to fibre mating means
- G02B6/3807—Dismountable connectors, i.e. comprising plugs
- G02B6/3833—Details of mounting fibres in ferrules; Assembly methods; Manufacture
- G02B6/3855—Details of mounting fibres in ferrules; Assembly methods; Manufacture characterised by the method of anchoring or fixing the fibre within the ferrule
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/24—Coupling light guides
- G02B6/42—Coupling light guides with opto-electronic elements
- G02B6/4201—Packages, e.g. shape, construction, internal or external details
- G02B6/4219—Mechanical fixtures for holding or positioning the elements relative to each other in the couplings; Alignment methods for the elements, e.g. measuring or observing methods especially used therefor
- G02B6/4236—Fixing or mounting methods of the aligned elements
- G02B6/4237—Welding
Abstract
Description
- 1. Field of the Invention
- This invention relates generally to a technique for attaching a ferrule to a fiber optic cable and, more particularly, to a technique for attaching a ferrule to a fiber optic cable that employs a cold welding operation.
- 2. Discussion of the Related Art
- Certain photonic devices, such as photodetectors, laser diodes and optical modulators, are sometimes mounted within a housing or device module as part of a device package assembly. A fiber optic cable, including a coaxially formed fiber jacket and optical fiber, is mounted to the module and is aligned with the photonic device. The optical fiber either delivers an optical signal to the photonic device or receives an optical signal generated by the optical device for transmission. The optical fiber can be a single mode fiber, and sometimes a polarization maintaining single mode fiber, requiring high precision optical coupling between the photonic device and the optical fiber, sometimes with sub-micron accuracy. Sometimes a lens is employed between the photonic device and the optical fiber to provide efficient optical coupling therebetween to reduce optical losses. The fiber optic cable is sometimes attached to a specialized optical adaptor outside the module to be coupled to a suitable optical system.
- Because the cable is flexible and has a very small diameter, a ferrule is used to hold the fiber at the desired location to provide proper alignment between the photonic device and an end of the optical fiber. The fiber cable is inserted into the ferrule so that the optical fiber extends out of an end of the ferrule. The ferrule is then positioned within an orifice in the module and mounted thereto so that an end of the fiber is positioned proximate to and aligned with the photonic device. When the fiber is in the desired location, the ferrule is secured to the module by laser welds or by epoxy. Automated alignment and laser welding systems are known in the art, such as the Newport Corporation laser weld work station (LWWS), that provide the desired alignment accuracy. The fiber optic cable is secured to the ferrule and the ferrule is secured to the module in a manner that provides a hermetic seal so that the photonic device is not contaminated by the environment.
- Various techniques are known in the art for securing the fiber optic cable to the ferrule. One conventional technique is to glue the fiber optic cable to the ferrule with an epoxy that contains an organic resin. The epoxy is cured at a temperature of approximately 150-165° C. to provide the bond. However, the heat of the curing process acts to deteriorate the fiber jacket around the optical fiber which reduces fiber protection. Additionally, the curing process causes the organic resin to generate out-gassing into the ferrule which decreases it hermetic integrity.
- To overcome the drawbacks of the epoxy process, it is known to employ a soldering technique to secure the fiber optic cable to the ferrule, where the ferrule is soldered to the optic fiber cable. However, the soldering technique dissipates heat from the soldering point to the fiber jacket that causes the jacket polymer to melt and deform reducing its integrity. Further, both the epoxy technique and the soldering technique are labor intensive, increasing the manufacturing costs.
- In accordance with the teaching of the present invention, a cold welding technique is employed for securing a fiber optic cable to a ferrule. The fiber optic cable is inserted into a sleeve so that an end of an optical fiber therein is substantially flush with an end of the sleeve. The fiber optic cable and sleeve assembly is then slid into a sleeve bore through one end of the ferrule so that the fiber is aligned with a narrow fiber bore in the ferrule. The fiber cable is then pushed through the sleeve so that the fiber extends through the fiber bore and out of an opposite end of the ferrule. The sleeve is then retracted from the ferrule while maintaining the relative positions of the ferrule and the fiber optic cable. The sleeve, ferrule and fiber cable assembly is then mounted in a fixture that is immersed in a cold plating bath. The cold plating process is performed so that a layer of a suitable plating material is deposited over the end of the ferrule through which the fiber extends so that the fiber optic cable is held within the ferrule, and the ferrule is hermetically sealed. The sleeve is then slid back into the ferrule, and is optically soldered to the fiber jacket of the cable to hold it in the desired location.
- Additional objects, advantages and features of the present invention will become apparent from the following description and appended claims, taken in conjunction with the accompanying drawings.
- FIGS.1-6 show an assembly process for securing a fiber optic cable to a ferrule employing a cold plating technique, according to an embodiment of the present invention;
- FIG. 7 is a plan diagram showing the assembled optical cable and ferrule immersed within a cold plating bath;
- FIG. 8 is an exploded perspective view of a fixture employed in the cold plating technique of the invention;
- FIG. 9 is a reverse exploded perspective view of the fixture shown in FIG. 8;
- FIGS.10-14 show various views of some of the components of the fixture shown in FIGS. 8 and 9;
- FIG. 15 is a perspective view of the assembled fixture; and
- FIG. 16 is a cross-sectional view of the assembled fixture of the invention, and including a fiber optic cable and ferrule assembly.
- The following discussion of the embodiments of the invention directed to a cold plating process for securing a fiber optic cable to a ferrule is merely exemplary in nature, and is in no way intended to limit the invention or its applications or uses.
- FIG. 1 is a length-wise, cross-sectional view of a fiber
optic cable 10 positioned within asleeve 12. Thecable 10 includes anoptical fiber 14 having a core and cladding layer, afiber buffer layer 18 and afiber jacket 20, all being coaxial therewith as shown. In this embodiment, thefiber 14 is a single mode fiber in that it transmits a single mode of light. As is known in the art, the cladding layer has an index of refraction that is less than the index of refraction of the core so that light entering the core at a certain angle of incidence or below is trapped therein by the cladding layer. Thesleeve 12 is a tube having aninternal bore 16 and is made of a suitable material, such as glass, metal or a ceramic. - The
buffer layer 18 and thefiber jacket 20 are protective layers formed over thefiber 14. In one embodiment, thefiber 14 is doped glass and thebuffer 18 and thejacket 20 are made of a suitable protective material, such as a polymer (acrylate polymer, Teflon™, etc.). As shown, the outer diameter of thejacket 20 is about the same as the inner diameter of theinternal bore 16 of thesleeve 12. Thus, when the fiberoptic cable 10 is slid into thesleeve 12, it is held in a certain location for alignment purposes. The end of thefiber 14 is substantially flush with an end of thesleeve 12, and does not extend out of thesleeve 12. - FIG. 2 shows the fiber optic cable and sleeve assembly inserted into a sleeve bore24 through one end of a
ferrule 26. Theferrule 26 can be made of any suitable material, such as Kovar, copper, metalized glass, ceramic, etc., as is known in the art. Theferrule 26 has one suitable shape shown here, however, can have other suitable shapes in other embodiments. In this configuration, thefiber 14 aligns with afiber bore 28 extending through an opposite end of theferrule 26. The sleeve bore 24 and thefiber bore 28 are coaxial with each other, and are connected by atapered bore 30 therebetween, as shown. The transition between the sleeve bore 24 and thetapered bore 30 defines anedge 32 therebetween. Thesleeve 12 is slid into the sleeve bore 24 until an end of thesleeve 12 contacts theedge 32. - FIG. 3 shows the
fiber cable 10 pushed through thesleeve 12 so that thefiber 14 goes through the fiber bore 28 and extends out of anend 40 of theferrule 26, as shown. Thesleeve 12 is maintained in place because it is forced against theedge 32. Thebuffer layer 18 is pushed against the tapered bore 30, as shown, in this configuration. A length of thefiber 14 is exposed from the buffer layer 18 a predetermined amount so that when thefiber cable 10 is pushed through thesleeve 12 and thebuffer layer 18 contacts the tapered bore 30, thefiber 14 extends out of theend 40 of the ferrule 26 a predetermined distance suitable for an electroplating process, as will be discussed below. Once theoptical fiber 14 is pushed through thesleeve 12, as shown in FIG. 3, thesleeve 12 is retracted from theferrule 26 so that it is outside of theferrule 26, as shown in FIG. 4. - According to the invention, a cold welding or electroplating process is performed to hermetically seal the fiber bore28 and hold the
cable 10 in place within theferrule 26. As shown in FIG. 5, the electroplating process, discussed below, has been performed, where alayer 50 of material is deposited around theend 40 of theferrule 26 and around thefiber 14 where it extends out theend 40. The electroplating process can use any suitable material, including, but not limited to, nickel and copper, and can be flashed with gold to prevent corrosion. Because the sleeve bore 24 is open during the electroplating process at the opposite end, out-gassing from the process does not affect the hermetic seal integrity of theferrule 26. Thelayer 50 seals the opening through which thefiber 14 extends out of theferrule 26 so that contamination from the environment does not enter the photonic device module through thebores ferrule 26. Once the electroplating process is complete, thesleeve 12 is slid back into theferrule 12, and is optically soldered to theferrule 26 at solder points 52, as shown in FIG. 6. - FIG. 7 is a simplified plan view of the process for electroplating the
end 40 of theferrule 26, as discussed above. In this diagram, the ferrule and cable assembly, as shown in FIG. 4, is inserted into atank 60 holding anelectrolyte 62. Afirst electrode 64 made of the electroplating material is inserted into thetank 60, and is electrically connected to a positive terminal of avoltage source 66. Asecond electrode 68 is coupled to the negative terminal of thesource 66. Thesource 66 is activated, and material from theelectrode 64 is transferred to theelectrode 68 through theelectrolyte 62. Because the current density is very high around the edge of the fiber bore 28, electroplating is performed faster at this location. The electroplating process coaxially and hermetically seals the gap between theferrule 26 and thefiber core 28. The process is performed at a temperature typically about 60° C., which is well below the threshold temperature that causes fiber jacket damage. - As discussed above, the invention includes cold welding or electroplating an end of a ferrule to hermetically seal an opening in the ferrule around a fiber extending out of the ferrule. FIG. 7 and the related text describes the electroplating process to form the
layer 50. In a practical environment, it would be desirable to accurately limit the area of theend 40 of theferrule 26 that is electroplated, and simultaneously electroplate many ferrule and fiber cable assemblies. According to another embodiment of the present invention, a cold welding fixture is provided to perform this process. - FIG. 8 is an exploded perspective view and FIG. 9 is a reverse exploded perspective view of a
cold welding fixture 70 used for this purpose, according to an embodiment of the present invention. FIGS. 10-14 show various views of assembled components of thefixture 70, and FIG. 15 is a perspective view of the assembledfixture 70. In this embodiment, thefixture 70 is able to simultaneously electroplate eighteen ferrule and fiberoptic cable assemblies 72, six of which are shown, each including aferrule 74 and afiber 76. However, in other embodiments, manymore assemblies 72 can be simultaneously electroplated. - As will be discussed in detail below, the
fixture 70 includes abase plate 78 including alower disc portion 82 and anupper disc portion 82 that are concentric with each other and define arim 84 therebetween. Thefixture 70 further includes twotest plates main body 90 and acover 92 including opposingsemicircular cover sections - The
test plates bolts 98 withinextended cavities bottom surface 106 of abody platform 108 and defined in arecess 110 of thebody 90. Thetest plates layer 50. Themain body 90 is then positioned on thebase plate 78 so that abottom edge 114 of themain body 90 rests on set screws extending through therim 84, and theupper disc portion 82 of thebase plate 78 extends into therecess 110. An O-ring 116 is positioned within acircular groove 118 formed in theplatform 108 of thebody 90, as shown. - The
assemblies 72 are then inserted into specially designedopenings 120 extending through theplatform 108 that match the shape of theferrule 74. Theassemblies 72 extend through theopenings 120 until thefibers 76 contact atop surface 122 of theupper portion 82 of thebase plate 78. In this position, theferrule 74 is pressed against an edge of theopening 120 so that only a portion of the end of the ferrule protrudes into therecess 110. Arecess 124 in the top of theplatform 108 accommodates the electrodes for the electroplating process. - An inside edge of the
cover sections cover sections main body 90 against the O-ring 116 so that the optic cables are positioned against the rubber strips 126 and 128. Screws are then threaded throughholes 130 in thecover sections main body 90. Thefixture 70 is then immersed in an electroplating bath to provide theelectroplating layer 50 on theassemblies 72 as discussed above. - FIG. 16 is a cross-sectional view of the
cold welding fixture 70, showing one of theassemblies 72 mounted therein.Electrodes 138 are positioned within therecess 124, as mentioned above.Bolts holes 130 are used to secure thecover sections main body 90, and to hold theelectrodes 138 in place. Abolt 144 extends through thetest plate 86, themain body 90 and thecover section 94, and secures an L-shapedelectrode 146 to a top surface of thecover section 94 by anut 148, as shown. Likewise, abolt 150 extends through thetest plate 88, themain body 90 and thecover section 96, and secures an L-shapedelectrode 152 to a top surface of thecover section 96 by anut 154, as shown. During electroplating, theelectrodes power source 66 to provide electrical current to theelectrodes 138 in therecess 124, and to thetest plates test plates ferrule 74. - The gap between the
surface 106 and thesurface 122 in therecess 110 is set byset screws rim 84. Thus, theedge 114 rests on theset screws fiber 76 just touches thetop surface 122. Thus, the gap can be set for different length fibers extending from theferrule 74. - The foregoing discussion discloses and describes merely exemplary embodiments of the present invention. One skilled in the art will readily recognize from such discussion and from the accompanying drawings and claims, that various changes, modifications and variations can be made therein without departing from the spirit and scope of the invention as defined in the following claims.
Claims (18)
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US10/001,539 US6558047B1 (en) | 2001-11-14 | 2001-11-14 | Cold welding process for fiber optic/ferrule attachment |
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US10/001,539 US6558047B1 (en) | 2001-11-14 | 2001-11-14 | Cold welding process for fiber optic/ferrule attachment |
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US20030091296A1 true US20030091296A1 (en) | 2003-05-15 |
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Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20070092184A1 (en) * | 2005-10-26 | 2007-04-26 | Nichia Corporation | Optical component, light emitting device, and method for manufacturing optical component |
RU2607164C2 (en) * | 2011-08-09 | 2017-01-10 | Алькон Рисерч, Лтд. | Multidrop laser surgical probe using polyhedral optical elements |
WO2021005837A1 (en) * | 2019-07-09 | 2021-01-14 | 株式会社フジクラ | Ferrule structure, protective tube structure, production method for ferrule structure, chip with ferrule structure, and production method for mounting board |
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US6749893B2 (en) * | 2002-01-31 | 2004-06-15 | Dalsa Semiconductor Inc. | Method of preventing cracking in optical quality silica layers |
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US6275369B1 (en) * | 1997-11-13 | 2001-08-14 | Robert A. Stevenson | EMI filter feedthough terminal assembly having a capture flange to facilitate automated assembly |
GB2339300B (en) * | 1998-07-06 | 2002-10-16 | Bookham Technology Ltd | A hermetically sealed optic fibre package and method of assembly |
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Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20070092184A1 (en) * | 2005-10-26 | 2007-04-26 | Nichia Corporation | Optical component, light emitting device, and method for manufacturing optical component |
EP1780564A3 (en) * | 2005-10-26 | 2007-05-09 | Nichia Corporation | Optical fibre with fluorescent tip cap and methods of manufacturing |
US7600924B2 (en) | 2005-10-26 | 2009-10-13 | Nichia Corporation | Optical component, light emitting device, and method for manufacturing optical component |
RU2607164C2 (en) * | 2011-08-09 | 2017-01-10 | Алькон Рисерч, Лтд. | Multidrop laser surgical probe using polyhedral optical elements |
WO2021005837A1 (en) * | 2019-07-09 | 2021-01-14 | 株式会社フジクラ | Ferrule structure, protective tube structure, production method for ferrule structure, chip with ferrule structure, and production method for mounting board |
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