Fiberoptic Couplers Having Spacer Fibers That Have No Optical Cores

This patent application is related to U.S. Pat. No. 5,121,452, issued Jun. 9, 1992, entitled "Fiberoptic Powersplitter" and U.S. Pat. No. 5,166,994, issued Nov. 24, 1992, entitled "Low Cost 1.times.8 Single Mode Optical Fiber Coupler", both of which are incorporated by reference as if fully set forth herein.

The invention relates to a multifiber fiberoptic coupler.

In general, fiberoptic couplers are created for the purpose of splitting the optical power in an optical fiber to two or more optical fibers or, conversely, to couple optical power present in two or more optical fibers into an optical fiber.

As described in earlier publications that are too numerous to be described individually, the fiberoptic couplers are made either by fusing or by bonding two or more optical fibers in a coupling region. The key to a successful coupler fabrication is a good control over the placement of the fibers brought into contact with each other in the coupling region prior to the fusion or bonding. For example, in the fusion process, imperfections such as insufficient contact between the fibers, dirt on the fiber surfaces, imbalances in tension forces applied to the fibers prior to the application of fusion heat, and three-dimensional non-uniformities in the applied heat could result in a low fabrication yield of couplers.

Fiberoptic couplers have been previously fabricated using two, three, or more bonded or fused optical fibers. The geometrical considerations attained in the coupling region substantially govern the coupling ratio between the individual optical fibers of the fiberoptic couplers; this is particularly true for couplers formed by identical optical fibers.

A simple known approach to fabricating a coupler is fusing two optical fibers to create a 2.times.2 coupler. If fiberoptic couplers of more than two optical fibers are needed, they are frequently fabricated by combining several 1.times.2 couplers in a tree or star like formation. However, this type of formation is not only fragile due to the vulnerability of the interconnecting fibers between the couplers but also bulky; this creates some difficulties in packaging.

Fused couplers have been made from seven identical optical fibers, wherein six fibers are arranged around a seventh inner fiber. In this geometry, the six outer optical fibers can be arrayed in perfect symmetry around an identical central optical fiber so that each of the surrounding fibers will contact both of its neighboring fibers and the central fiber in the same manner. Such perfect symmetry is not possible with other numbers of identical fibers.

Another prior approach to aligning and maintaining reliable contact among fibers prior to and during the fusion employs using a surrounding structure such as a tube made of an optical material. It is necessary to treat the surrounding tube on the optical fibers and the entire assembly is then heated and drawn in the fuse-drawing process. In some arrangements, it is difficult to maintain the threaded fibers precisely aligned prior and during the fusion process.

Couplers using less than seven identical optical fibers have been difficult to make since it is relatively difficult to obtain a periodic spacing and a uniform contact of the surrounding fibers. This is a disadvantage because many fiberoptic power distribution systems require equal power splitting in multiples of four optical fibers.

Thus, there is a need for a multifiber coupler design that is easy to fabricate, has a high fabrication yield and can accommodate a variable number of identical optical fibers with selected power distribution.

In one aspect, the invention features a multifiber fiberoptic coupler formed by a bundle of two or more optical fibers, and one or more spacer (or dummy) fibers. The optical fibers include a core and a surrounding cladding. The dummy fibers are made of optical material with the refraction index appropriately matched to the refraction index of the cladding and are adapted to maintain a proper position of the optical fibers. The spacer fibers do not contain a core and thus are not able to support a guided light mode, i.e., carry substantial amount of energy. The entire bundle of fibers is fused and drawn in a single location to form an integrated fused coupler. The spacer fibers are used for achieving a desired arrangement of the optical fiber; this enables formation of fiberoptic couplers with desired coupling ratio, improved uniformity and repeatable structure.

In one preferred embodiment, the optical fibers and the spacer fibers are all of the same size and cross-section, arranged and fused together in a side-by-side configuration about the central fiber. The resulting coupler can be easily made with a high yield and is very robust and environmentally rugged.

In another aspect, the invention features fiberoptic coupler comprising multiple optical fibers each having a core and a surrounding cladding, at least one spacer fiber having the refraction index substantially matched to the refraction index of the cladding of at least one adjacent optical fiber. The optical and spacer fibers are arranged, over a region extending axially through a limited length coupling region, in a side-by-side configuration wherein each fiber touches neighboring fibers. The coupling region is created by laterally fusing all the fibers and is adapted to couple propagating modes of light between the optical fibers.

Preferred embodiments of this aspect of the invention may include one or more of the following features.

The fiberoptic coupler is formed by a center spacer fiber surrounded by the optical fibers arranged in a close-packed configuration, wherein the diameter of the spacer fiber is selected to enable close packing of the neighboring optical fibers.

The configuration and the number of the fibers of the fiberoptic coupler is selected to achieve wavelength dependent coupling of modes between an input optical fiber and an output optical fiber.

The fiberoptic coupler is formed by seven equal diameter fibers with a center fiber surrounded by six fibers. The center fiber of the configuration may be an optical fiber and at least one of the six surrounding fibers is the spacer fiber. Alternatively, the center fiber may be a spacer fiber.

The fiberoptic coupler may be formed by six fibers surrounded by a second ring of twelve close-packed spacer fibers.

The fiberoptic coupler may be formed by a close-packed configuration of nineteen equal diameter fibers with a center fiber surrounded by a first ring of six close-packed fibers and a second ring of twelve close-packed fibers. The center fiber may be an optical fiber and at least one of the eighteen surrounding fibers is a spacer fiber. Alternatively, the center fiber may be a spacer fiber.

The coupling region is formed by a fuse-drawing process and its length may be designed to achieve a selected coupling ratio.

The geometry of the optical fibers configuration may be selected to achieve a desired coupling ratio between the optical fibers.

The fiberoptic coupler may be formed by fibers arranged linearly side-by-side to form a ribbon like structure with each fiber touching its neighboring fibers. In the ribbon like structure, the geometry of the fiber configuration and the number of the fibers may be selected to achieve wavelength dependent coupling of modes between an input optical fiber and an output optical fiber.

In another aspect, the invention features a 1.times.4 symmetric fiberoptic coupler comprising five equal diameter optical fibers each having a core and a surrounding cladding and two spacer fibers having the refraction index substantially matched to the refraction index of the cladding of the optical fibers. One of the optical fibers is located in the center and other four optical fibers and the two spacer fibers are located substantially symmetrically as a ring of six fibers around the central optical fiber forming a close-packed configuration. The fibers are extended axially through a limited length coupling region, created by a fuse-drawing process, and are adapted to couple propagating modes of light between the optical fibers.

In another aspect, the invention features a 1.times.8 symmetric fiberoptic coupler comprising nine equal diameter optical fibers each having a core and a surrounding cladding and ten spacer fibers having the refraction index substantially matched to the refraction index of the cladding of the optical fibers. One optical fiber is located in the center and is surrounded by a ring of six spacer fibers. A second ring of twelve fibers formed by eight optical fibers and two spacer fibers is located substantially symmetrically around the central optical fiber to form a close-packed configuration. The fibers extend axially through a limited length coupling region, created by a fuse-drawing process, and are adapted to couple propagating modes of light between the optical fibers.

In another aspect the invention features a fiberoptic coupler comprising multiple optical fibers each having a core and a surrounding cladding and multiple spacer fibers having the refraction index substantially matched to the refraction index of the cladding of at least one adjacent optical fiber. The optical fibers are arranged in groups of two or more fibers located in close proximity and separated by at least one spacer fiber. All fibers are placed side-by-side and extend axially through a limited length coupling region. The coupling region is created by laterally fusing the fibers and is adapted to couple propagating modes of light between the optical fibers in each the group. The spacer fibers are adapted to substantially eliminate coupling of modes of light between different groups of fibers.

The various fiberoptic couplers may use single mode optical fibers or multimode optical fibers.

In another aspect, the invention features a multicoupler unit that includes a bundle of two or more side-by-side pairs of optical fibers isolated by at least one spacer fiber and a large separator fiber of appropriately matched index of refraction to separate the optical fibers from each other. This bundle is fused and drawn in a single location to form an integrated rigid structure in which each pair of adjacent optical fibers forms a fused biconical coupler having respective optical fiber leads. The individual couplers are optically "insulated" from each other by the mass of transparent optical material provided by the separator fibers. This embodiment allows a multiplicity of optical couplers to be intercoupled in a smaller junction where fewer housings are required.

FIG. 1 is a side view of a symmetrical coupler formed by a fuse drawing process of seven optical or spacer fibers of an identical diameter arranged in a close-packed configuration in accordance with the present invention.

FIG. 1A is a side view of the coupler of FIG. 1 formed by twisting the fiber configuration.

FIG. 2 is a cross-sectional view of the coupler of FIG. 1 in the 2--2 direction.

FIG. 3 is a cross-sectional view of the fiberoptic coupler of FIG. 1 in the 3--3 direction.

FIGS. 4A through 4G are cross-sectional views of various 1.times.N or M.times.N embodiments of the fiberoptic coupler of FIG. 1.

FIG. 4H is a cross-sectional view of a 6.times.6 embodiment of the fiberoptic coupler of FIG. 1.

FIG. 4I is a cross-sectional view of the 1.times.4 fiberoptic coupler of FIG. 4B also including a second level of twelve close-packed spacer fibers.

FIG. 5 is a cross-sectional view of a symmetrical nineteen fiber fiberoptic coupler with optical fibers and spacer fibers arranged in a close-packed configuration in accordance with the present invention.

FIGS. 5A through 5D are cross-sectional views of various embodiments of 1.times.N or M.times.N the fiberoptic coupler of FIG. 5.

FIG. 5E is a cross-sectional view of an 8.times.8 embodiment of the fiberoptic coupler of FIG. 5.

FIGS. 6A through 6C are cross-sectional views of linear fiberoptic couplers in accordance with the present invention.

FIGS. 7A through 7B are cross-sectional views of several fiberoptic couplers separated by at least one spacer fiber, all integrated into one fiberoptic coupler structure.

FIG. 1 is a side view and FIG. 2 a cross-sectional view of a symmetrical bundle 10 formed by optical fibers 11, 13, 15, 17, and 19 and spacer fibers 21, and 23 positioned in a close-packed hexagonal arrangement, before fusion. Each optical fiber (single mode, multimode fiber, etc.) includes a core (labeled 11a, 13a, 15a, 17a, and 19a) and a cladding (labeled 11b, 13b, 15b, 17b, and 19b). Spacer (or "dummy") fibers 21 and 23 are fabricated from optically pure material with a refractive index matched to the refractive index of the cladding of the neighboring optical fibers. Since the spacer fibers do not have a core, they are unable to support propagation of a guided light mode; this substantially eliminates losses through the spacer fiber. Bundle 10 is formed by the uniform hexagonal structure of the same diameter fibers, wherein a central fiber is surrounded by a ring of fibers each having contact with the central fiber and neighboring films. Such configuration is mechanically stable and readily amenable to fusion and drawing.

Bundle 10 is fused and drawn to form a tapered coupling region 25 shown in a cross-sectional view in Fig. 3. Prior to the fusion process, the fiber coating is removed in and around coupling region 25 of each optical fiber, and the individual fibers are arranged and aligned side-by-side. Then, bundle 10 is mounted into clamps of two translation stages. A heat source of an appropriate shape (e.g., a torch, a resistance heated wire, a laser) is applied over a relatively narrow region of bundle 10 until a suitable working temperature is obtained. Subsequently, one or both translation stages are activated to elongate the heated region of bundle 10 by performing unidirectional or bi-directional drawing. While the fusing is performed, light is launched into one of the optical fibers at the input side of the coupler and detected at another optical fiber at the output side of the coupler. The drawing is continued until the amount of light coupled between the fibers reaches a predetermined relationship. To create a radial force that facilitates a good coupling of the fibers, bundle 10 may be twisted prior to or during the fusion, as shown in FIG. 1A. Depending on the type of the coupler or the desired coupling ratio, the coupling region may have a fractional turn or several turns.

After the fuse-drawing process, the diameter of the coupling region is less than one fourth of the original size. The fused portion of the resulting coupler is several millimeters to few centimeters long depending on the coupling ratio and degree of fusion. In the cross-section of the fused coupling region (FIG. 3) cores 11a, 13a, 15a, 17a, and 19a of the respective optical fibers are situated in sufficiently close positions so that a desired optical coupling of propagating light modes occurs. The coupling depends on the distances between the fiber cores, as known in the art.

Following the drawing process, the fibers extending from the coupling region are bonded on a rigid, slotted cylindrical substrate using an adhesive. The coupling region is suspended in air above the slotted area on the substrate. The bonds are designed to isolate and relieve the strain on the coupling region from external forces. This structure is then enclosed in a polymer tube and an adhesive sealant is used at the end of the polymer tube to protect the coupler. For the final protection, the entire structure may be encapsulated in a stainless steel tube.

Different embodiments of the multifiber coupler, formed by the spacer fibers 32 and the optical fibers 34, are shown in cross-sectional views in FIGS. 4A through 4I, The coupler arrangement of FIG. 4A may be used as a 1.times.6 or 1.times.5 coupler and, similarly, the coupler arrangement of FIG. 4B may be used as a 1.times.5 or 1.times.4 coupler depending on the use, the desired coupling ratio, and whether the central input fiber is also utilized as an output fiber. In many applications wherein light of several wavelengths (e.g., 1300 nm and 1550 nm) is multiplexed for simultaneous transmission and distribution, it is important to fabricate couplers that have a wavelength independent coupling ratio. To obtain the wavelength independent coupling ratio, the coupler is drawn in the fusion process to an extreme wherein 100% of the input light is distributed to the surrounding optical fibers. Alternatively, light carried by several optical fibers, each may have a different wavelength or modulation frequency, is combined in the coupler and carried out in the centrally located output fiber.

FIG. 4B shows an important 1.times.4 embodiment of the present invention. The central input, optical fiber is symmetrically arranged with respect to the output fibers so that each of the output fibers carries substantially equal amount of light. The symmetry of the optical fibers, their locations with respect to each other and the extent of the fuse-drawing govern the coupling ratio. The spacer fibers, which in general can have different sizes and refraction indexes, enable proper positioning of the optical fibers and easy manipulation of the fiber bundle.

By achieving desired symmetrical or asymmetrical locations of the fiberoptic cores in the coupling region, standardized couplers with desired coupling ratios are fabricated. For example, for a fiberoptic coupler that exhibits a wavelength dependent coupling ratio, it is advantageous to form the coupling region with linearly arranged optical fibers, as shown in FIGS. 4E, 4G, or 5D. The spacer fibers maintain the desired distance of the fiber cores and thus the coupling ratio. Furthermore, the spacer fibers complete the close packed structure that is easy to handle during the coupler fabrication.

Referring to FIG. 4I, in another embodiment, a separate protection layer around the coupling region of the coupler of FIG. 4B is created by surrounding bundle 10 with twelve spacer fibers prior to the fusion process. In the fuse-drawing process, the spacer fibers form a glass barrier, i.e., an extending cladding, that protects the coupling region and reduces the effects of the external environment.

Referring to FIG. 4H, in another embodiment the multifiber coupler is a 6.times.6 symmetrical coupler formed by six optical fibers that surround a central spacer fiber. The equal diameter spacer fiber enables a easy positioning and symmetric packing of the optical fibers. A coupler with a different number of similarly packed N.times.N fibers is fabricated using a central spacer fiber of a different diameter. The diameter sizes are described in Table 1 of the U.S. Pat. No. 5,121,452 patent. For example, a symmetrical 5.times.5 coupler has a central spacer fiber with a diameter reduced by a factor of 1.43.

Referring to FIG. 5, in another embodiment, the multifiber coupler features a 1.times.8 coupler arranged in a bundle 30. To achieve a substantially symmetrical arrangement and the close packing of the optical fibers, six spacer fibers 32 surround a centrally located optical input fiber 34. Optical output fibers 36 are located in a second ring (cylindrical layer) around the input fiber. As described above for the coupler of FIG. 1, bundle 30 is fused and drawn to form a tapered coupling region. The length of the coupling region correspond to a desired coupling ratio.

Different embodiments of the nineteen fiber coupler of FIG. 5 are shown in FIGS. 5A through 5E. The arrangement of spacer fibers 32 and optical fibers 34 and 36 is selected depending on the desired properties of the coupler. Referring to FIG. 5E, the nineteen fiber close-packed configuration is also used to fabricate a 8.times.8 coupler. In the 8.times.8 coupler, the central optical fiber is replaced by a spacer fiber of the same diameter, and the optical fibers of the second layer are used as both input and output fibers. Couplers that include a larger number of optical fibers (e.g., 9.times.9, 10.times.10, etc.) are within the scope of the present invention.

Referring to FIGS. 6A through 6C, in another embodiment optical fibers 36 and spacer fibers 32 are arranged linearly side-by-side to form a ribbon like structure. The multifiber coupler is again formed by fuse-drawing, as described above. The ribbon like structure may be twisted in the fusion process to provide improved coupling between the fibers. Since the coupling ratio at different wavelengths depends on the distance between the fiber cores, a desired wavelength dependent coupling ratio can be achieved by selecting a spacer fiber with a proper diameter or a suitable number of spacer fibers separating the optical fibers. This arrangement may be used to fabricate a wavelength dependent multiplexer (WDM).

Referring to FIGS. 7A and 7B, the use of spacer fibers enables fabrication of several fiberoptic couplers integrated into one rigid structure 40. Optical input fibers 42 and output fibers 44 are arranged side-by side to form a coupler 43. The individual couplers are separated by one or more spacer fibers 46 depending on the needed separation. The individual couplers are optically "insulated" from each other by the mass of transparent optical material provided by the spacer fibers. Fiber bundle 40 is fuse-drawn in a single location to form an integrated rigid structure. This embodiment allows close packing of several optical couplers, each having a selected geometry and coupling ratio.

It is within the scope of this invention to use spacer fibers of different sizes and shapes made of substantially homogeneous optical material. A tubular fiber may be also used as the spacer that maintains a desired distance between the fibers. In a fiberoptic structure that includes several fiberoptic couplers (FIGS. 7A through 7C), the tubular spacer fiber also creates air cladding for the coupling region.

In another embodiment, the coupling region of the described couplers is formed by a bonding process. The bonding is achieved using a 5 minute epoxy, UV epoxy or other suitable adhesives. Before or after the bonding material is applied, the fiber bundle may be tied together to exert an external radial force on the fibers. It is within the scope of the present invention to use etched or unetched optical fibers.

Other embodiments are within the scope of the following claims: