CN212915694U

CN212915694U - Multi-fiber splicing device for splicing a plurality of first optical fibers and a plurality of second optical fibers

Info

Publication number: CN212915694U
Application number: CN201890001072.XU
Authority: CN
Inventors: 威廉·G·艾伦; 威廉·J·克拉塔诺夫; 唐纳德·K·拉森; 拉斯洛·马科斯; 柯蒂斯·E·梅尼斯; 丹尼尔·J·崔德威
Original assignee: 3M Innovative Properties Co
Current assignee: 3M Innovative Properties Co
Priority date: 2017-08-11
Filing date: 2018-08-03
Publication date: 2021-04-09
Anticipated expiration: 2028-08-03
Also published as: WO2019030635A1

Abstract

A multi-fiber splicing apparatus for splicing a plurality of first optical fibers and a plurality of second optical fibers is described. The multi-fiber splicing device comprises: a multi-fiber splice element having a body with a plurality of alignment channels configured to receive the plurality of first optical fibers and the plurality of second optical fibers in an end-to-end manner, wherein each of the first plurality of alignment channels has an arcuate profile; a clamp plate, wherein at least one of the body and the clamp plate is formed from a silica material having a coefficient of thermal expansion, and an optical coupling material is disposed in at least a portion of the plurality of alignment channels such that the optical coupling material is positioned between the first plurality of optical fibers and the second plurality of optical fibers. The silica material used to make at least one of the body and the splint is a net shape cast cured silica material.

Description

Multi-fiber splicing device for splicing a plurality of first optical fibers and a plurality of second optical fibers

Background

Technical Field

The present invention relates to a splicing element for splicing a first plurality of optical fibers and a second plurality of optical fibers.

RELATED ART

Communication network owners and operators face an increasing demand to deliver faster and better services to their customers. They can meet these demands for greater bandwidth by incorporating optical fibers into their networks. Fiber optic cables are used in optical networks to transmit signals between access nodes to transmit voice, video, and data information.

Some conventional fiber optic cables include fiber optic ribbons that include coated optical fiber groups arranged in a planar array. The optical fibers in the ribbon are generally arranged parallel to each other. Optical fiber ribbons are typically interconnected using multi-fiber optical connectors, such as MPO/MTP connectors, which may be used in data centers or other points in a network where parallel optical interconnections are desired.

Data centers rely on 10Gb/s and 40Gb/s transmission rates, which are relatively mature technologies. As the way people use the internet has changed, global data center Internet Protocol (IP) traffic is expected to increase by 31% each year between 2016 and 2021. See Hassen, O., "Three Trends drying the 100G Ethernet Market", Data Center Knowledge (Jan.25, 2016) (Three Trends in the push for the 100G Ethernet Market, Data Center Knowledge, 2016, 1/25 days) (see, all Three Trends in the Data Center, 2016, Inc.) (see, all Three Trends in the Data Center, 2016, 1/25 days, Data Centerhttp：//www.datacenterknowledge.com/archives/2016/01/25/ three-trends-driving-100g-ethernet-market/). Cloud computing, mobile device access to global video and social media content is pushing data centers to move from 10Gb/s and 40Gb/s transmission rates to 100Gb/s and 400Gb/s transmission rates.

Data centers are moving towards 40-100 Gb/s transmission rates that utilize multiple parallel network links, which are then aggregated to achieve higher overall data rates. The polarity in the fiber routing is essentially the matching of the transmit signal (Tx) and the receive equipment (Rx) at both ends of the fiber link by providing transmission over the entire fiber system to the receive connection. The polarity is managed by using transmit and receive pairs (duplex wiring), but becomes more complex for multi-fiber connections that support multiple duplex pairs, such as MPO/MTP connectors.

Higher bandwidth links will require more power to ensure signal transmission integrity. Heat dissipation of electronic devices has become a concern today, and further increases in power will exacerbate the problems that data centers have faced. This increasing demand for more power and the desire to install future flexible structured cabling systems is pushing interconnect performance towards low loss performance (less than 0.1dB per connection point).

Conventional single fiber ferrule type connectors are easy to reconfigure, but suffer from high optical loss (0.2 dB-0.3 dB) and even higher loss (0.35dB-0.7dB) for multi-fiber ferrule type connectors such as MPO/MTO connectors. Ferrule type connectors must be cleaned each time they are mated. Furthermore, the space required for the ferrule-type connector limits the interconnection density.

Fusion splicing is another conventional interconnection method that produces a low-loss, durable, reliable splice. However, handling 250 micron optical fibers during preparation, fusion and storage can be cumbersome. Today, such fusion splices typically require their own splice trays in data centers.

Finally, conventional gel-type mechanical splices provide a durable and reliable fiber splice with insertion losses that are better than connectors and approach that of fusion splices. However, these mechanical splices employ index matching gels that are not solid materials and therefore do not provide structural integrity.

Therefore, there is a need for new multi-fiber interconnect technologies that provide "fusion-like" optical performance to facilitate migration of data center bandwidth from today's 10Gb/s and 40Gb/s transmission rates to future 100Gb/s and 400Gb/s transmission rates.

Disclosure of Invention

In accordance with a first embodiment of the present invention, a multi-fiber splicing device is described that can be used to splice a plurality of first optical fibers and a plurality of second optical fibers. The multi-fiber splicing device comprises: a multi-fiber splice element having a body with a plurality of alignment channels configured to receive a plurality of first optical fibers and a plurality of second optical fibers in an end-to-end manner, wherein each of the first plurality of alignment channels has an arcuate profile; a clamp plate, wherein at least one of the body and the clamp plate is formed from a silica material having a coefficient of thermal expansion, and an optical coupling material is disposed in at least a portion of the plurality of alignment channels such that the optical coupling material is positioned between the first plurality of optical fibers and the second plurality of optical fibers. The silica material used to make at least one of the body and the splint is a net shape cast and cure (net shape) silica material.

In another aspect of the first embodiment, the clamp plate of the multi-fiber splicing device is a thin flexible glass clamp plate that is bent to further align and secure the terminal ends of the first and second plurality of optical fibers in the interconnection area of the multi-fiber splicing element. The multi-fiber splicing apparatus further includes means for applying a compressive force on the clamping plate that causes the clamping plate to bend and thereby align and secure the terminal ends of the plurality of first optical fibers and the plurality of second optical fibers in the alignment channels in the interconnection region of the multi-fiber splicing element.

In accordance with a second embodiment of the present invention, a multi-fiber splicing device is described that can be used to splice a plurality of first optical fibers and a plurality of second optical fibers. The multi-fiber splicing device comprises: a multi-fiber splicing element having a body with a plurality of alignment channels configured to receive a plurality of first optical fibers and a plurality of second optical fibers in an end-to-end manner; a clamp plate, wherein the clamp plate is a thin flexible glass clamp plate that is bent to align and secure the terminal ends of the first and second plurality of optical fibers in the interconnection region of the multi-fiber splicing element; wherein at least one of the body and the clamp plate is formed of a silica material having a coefficient of thermal expansion and an optical coupling material is disposed in at least a portion of the plurality of alignment channels such that the optical coupling material is positioned between the first plurality of optical fibers and the second plurality of optical fibers. The silica material used to make at least one of the body and the splint is a net shape cast cured silica material.

In one aspect of an embodiment, the optical coupling material is at least one of an index matching material or an optical adhesive, and when the optical coupling material is an optical adhesive, the optical adhesive is curable via actinic radiation to form a durable multi-fiber optical splice. In particular, the optical adhesive is a blue light curable adhesive. Exemplary optical adhesives include adhesive compositions that include non-aggregated, surface-modified silica nanoparticles dispersed in an epoxy resin.

In another aspect of the embodiments, the alignment passage of the multi-fiber splice device has an arcuate profile including a generally planar portion at an entrance opening at either end of the alignment passage, the alignment passage slowly ascending between the entrance opening and an interconnection region centrally located on the body, and wherein the alignment passage culminates in a shallow dome within the interconnection region.

According to a third embodiment of the present invention, there is described an optical box comprising: a housing having a top, a bottom, and a plurality of sidewalls disposed between the top and the bottom; and an element housing disposed through one of the plurality of side walls. A multi-fiber splice element disposed in the element housing to interconnect the terminal ends of the plurality of external optical fibers to the plurality of terminal ends of the optical fibers disposed within the housing, wherein the multi-fiber splice element has a body with a plurality of alignment channels configured to receive the plurality of first optical fibers and the plurality of second optical fibers in an end-to-end manner; a clamp plate, wherein at least one of the body and the clamp plate is formed of a coefficient of thermal expansion matched silica material; and an optical coupling material disposed in at least a portion of the plurality of alignment channels such that the optical coupling material is positioned between the first plurality of optical fibers and the second plurality of optical fibers.

The plurality of signal paths exit the cassette through one of the plurality of side walls. In some embodiments, the plurality of signal paths include connection points at the sidewalls from which the plurality of signal paths exit the cassette. The connection point may be a fiber optic connector connection point or a fiber optic splice connection point. The connection points may be configured as single fiber connection points or multi-fiber connection points. In an exemplary use where the cassette includes single fiber connection points, the plurality of single fiber connector connection points are paired such that a first of the paired single fiber connection points is designated as a transmit port and a second of the paired single fiber connection points is designated as a receive port. In this aspect, signals carried by the plurality of external optical fibers may be reordered within the cassette such that the signals exit the cassette in a different order than they enter the cassette.

According to a fourth embodiment of the present invention, a method of splicing a plurality of first optical fibers to a plurality of second optical fibers is described. The method comprises the following steps: inserting a first plurality of optical fibers into a plurality of alignment channels formed in a multi-fiber silica splice element, wherein the plurality of alignment channels are configured to receive the first plurality of optical fibers and the second plurality of optical fibers in an end-to-end manner; inserting a second plurality of optical fibers into the plurality of alignment channels such that the terminal ends of the first plurality of optical fibers are in close proximity to the ends of the second plurality of optical fibers; and curing the optical adhesive disposed in the plurality of alignment channels by directing an effective amount of actinic radiation toward the optical adhesive. In some aspects, the curing step includes directing an effective amount of blue light through at least one of the plates toward the optical adhesive.

According to a fifth embodiment of the present invention, a plug and splice interconnection system is described, comprising: a multi-fiber splicing device including an element housing and a multi-fiber splicing element disposed in the element housing to interconnect terminal ends of optical fibers of a pair of optical fiber ribbons, wherein the multi-fiber splicing element has a body with a plurality of alignment channels configured to receive the terminal ends of the optical fibers in an end-to-end manner; a clamp plate, wherein at least one of the body and the clamp plate is formed of a low coefficient of thermal expansion silica material; and a bare multifiber fiber holder that receives a prepared end of an optical fiber from one of the pair of ribbons, wherein the prepared end is introduced into the alignment channel of the multifiber splicing element when the bare multifiber fiber holder is connected to the multifiber splicing device.

An exemplary interconnection system may include a clamp plate that is a thin, flexible glass clamp plate that is bent to align and secure the terminal ends of the optical fibers in the interconnection area of the multi-fiber splice element.

A multi-fiber bare fiber holder of an interconnection system comprising: a strap anchor; an optical fiber alignment mechanism to align and protect prepared ends of a plurality of optical fibers from one of a pair of optical fiber ribbons; and a locking mechanism to secure the bare multifiber fiber holder to the multifiber splicing device. In some aspects, the fiber alignment mechanism is a fiber alignment collar slidably mounted in the multi-fiber bare fiber holder, and in other aspects, the locking mechanism is a locking sleeve configured to be connected to a component housing of the multi-fiber splicing device.

The example interconnection system may also include an optical coupling material disposed in at least a portion of the plurality of alignment channels such that the optical coupling material is positioned between the terminal ends of the optical fibers.

In some embodiments, the exemplary interconnection system is used to form a fiber bundle assembly when a multi-fiber splicing device and a multi-fiber bare fiber are connected.

In other embodiments, the exemplary interconnect system is disposed at least partially in a sidewall of the housing to form a fan-out box.

"actinic radiation" is radiation capable of initiating a photoreaction process. Actinic radiation may be generated by any light source that provides sufficient intensity at a wavelength suitable for the photoinitiator or photosensitizer used in the photoreactive composition.

The above summary of the present invention is not intended to describe each illustrated embodiment or every implementation of the present invention. The figures and the detailed description that follows more particularly exemplify these embodiments.

Drawings

The invention will be further described with reference to the accompanying drawings, in which:

fig. 1A-1C are three views of a splice element according to a first embodiment of the present invention.

Fig. 2A-2C are three views of a splicing process using the splice member of fig. 1A and 1B.

Fig. 3A and 3B are two cross-sectional views of the splice member shown in fig. 2B and 2C, respectively.

Figure 4 illustrates one application of the multi-fiber plug and splice interconnect of the present invention.

Fig. 5A and 5B are two exploded views illustrating the multi-fiber plug and splice interconnect multi-fiber splicing arrangement and multi-fiber bare fiber holder shown in fig. 4.

Fig. 6A-6C illustrate splicing of fiber optic ribbons in the plug and splice interconnection system of fig. 5A-5B.

While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.

Detailed Description

In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. In this regard, directional terminology, such as "top," "bottom," "front," "rear," "forward," and "aft," etc., is used with reference to the orientation of the figure(s) being described. Because components of embodiments of the present invention can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is in no way limiting. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention.

Telecommunication standards, such as the TIA 568.3-D fiber routing component standard, have defined three basic methods for handling polarization, namely ensuring that transmit and receive pairings are met by managing the various polarization components within the network link. The three basic approaches use multi-fiber cable assemblies with MPO/MTO connectors having various configurations of "key-up-to-key" links and "key-up-to-key-down" links, with optical fiber ribbons straight-through or fibers in ribbons "flipped in pairs".

In one embodiment of the present invention, conventional multi-fiber optical connectors that have little or no disconnection may be replaced by more permanent connections, such as multi-fiber splicing techniques as described herein.

In a first embodiment, an optical fiber splice includes an alignment mechanism and an optical coupling material. The alignment mechanism may be formed using a sol cast resin to produce a net-shaped silica ceramic part. In one aspect, the optical coupling material can be an optical adhesive that can be used to permanently secure a plurality of parallel optical fibers in an exemplary splice element. Exemplary optical adhesives can be cured with actinic radiation via a rapid and straightforward process using a visible (e.g., blue) LED light source. In an alternative aspect, the optical coupling material may be an index matching material configured to optimize signal transmission through the fiber splice, and the exemplary splice element provides a fiber splice with very low optical loss to achieve optical loss and reflection performance approaching the level of a fusion splice, thereby providing a reliable, low-loss, durable termination, which may be accomplished by minimally trained technicians.

In a first embodiment, fig. 1A-1C illustrate a bare fiber retention plate or splice element 100 configured to splice a plurality of parallel optical fibers 54, 54' of first and second fiber optic ribbons 50, as shown in fig. 2C. The body may have a generally rectangular parallelepiped, semi-cylindrical shape, or other shape having at least one generally planar major surface. The splice member 100 includes a splice body 101 having a first end 101a and a second end 101 b. The splice body 101 has an integral alignment mechanism that includes a plurality of alignment grooves or channels 112 that extend from a first end to a second end of the splice body. Each alignment channel is configured to guide and support a single optical fiber. In the exemplary embodiment shown in FIG. 1A, the splice element has 12 parallel aligned channels to splice together 2-12 fiber optic ribbons in an end-to-end configuration. In alternative embodiments, exemplary fiber optic splicing elements can have fewer or more alignment channels depending on the end application and the number of optical fibers to be spliced. Thus, in some embodiments, the splice element can have two parallel alignment channels for splicing a pair of duplex fiber optic cables.

In one embodiment, the alignment mechanism is configured to align a plurality of optical fibers, which are then bonded or spliced together end-to-end using an optical adhesive or a mechanical clamping device with or without an index matching gel. In some embodiments, the alignment channel 112 may be substantially flat or planar as it extends from the first and second ends to the interconnection area 105, which may be centrally disposed on the splice member 100. In another aspect, the alignment channel may have a generally arcuate profile to aid in inserting the optical fiber into position in the alignment channel. For example, the alignment passage 112 may include a generally planar portion 112a at the inlet openings or apertures 113A and 113b that rises slowly in a rising portion 112b between the inlet openings and the interconnecting portion 105, wherein the alignment passage peaks in a shallow dome 112c within the interconnecting region, as shown in fig. 3A.

In alternative embodiments, the alignment channels may be substantially flat when the alignment channels extend from the first end of the splice element to the second end of the element.

The alignment passage 112 may be continuous or may be discontinuous. In the exemplary embodiment shown in fig. 1A, the alignment channel is a continuous structure that extends from a first inlet opening 113a at the first end 101A of the splice body 101 to a second inlet opening 113b at the second end 101A of the splice body 101.

The optical fibers may be inserted into the alignment mechanism through the entrance openings or

holes

113a and 113 b. In some aspects, the

inlet apertures

113a, 113b may include funnel-shaped inlet portions formed by the tapering of the partitions 114 between adjacent channels to provide more direct fiber insertion. In other embodiments, the entrance aperture may be fully or partially tapered or funnel-shaped to guide the insertion of the optical fiber into the alignment passage 112.

The

inlet openings

113a, 113b are characterized by a channel pitch (i.e., the distance between the centerlines of adjacent aligned channels). In the embodiment shown in fig. 1A and 1B, the channel pitch at the first end of the splice member is the same as the channel pitch at the second end of the splice member. In this exemplary embodiment, the channel pitch is approximately the same as the inter-fiber spacing in a conventional 12-fiber ribbon. In alternative embodiments, the channel pitch at the first end of the splice member and the channel pitch at the second end of the splice member can be different. For example, the channel pitch at the first end of the splice element can be set to the fiber spacing of a conventional fiber optic ribbon, while the channel pitch at the second end of the splice element can be a different value, such as when splicing a single fiber or when splicing two or more smaller fiber optic ribbons or fiber optic modules to a larger ribbon fiber.

In the exemplary embodiment of fig. 1A and 1B, the entrance openings 113a, 113B are disposed in a common plane and all optical fibers spliced by the exemplary splice element enter the guide channel along the common plane. Alternatively, some of the inlet openings may be disposed on different planes that are vertically offset from the inlet openings. This may be useful when the inter-fiber spacing on one side of the splice element is different than the inter-fiber spacing on the second side of the splice element.

In another aspect, the splice element 100 can include a fiber comb portion 115 disposed adjacent the entrance openings or

apertures

113a and 113b on each side of the body 101. A fiber comb may be used to support, align and guide the optical fibers terminated in the exemplary splice element 100. The alignment passage 112 passes through the comb portion. The dividers between adjacent aligned channels in the comb portion may be taller than other portions along the aligned channels. The higher spacer portion 114a (fig. 1A and 3A) allows a single optical fiber to be offset from position by as much as one-half of the fiber diameter while still feeding into the correct alignment channel, thereby providing an automatic centering mechanism for the optical fiber in the alignment channel.

The splice element 100 can also include a clamping plate 120 (shown in fig. 1B and 1C), wherein the clamping plate can be a flat transparent plate disposed at least over the interconnection region 105 of the splice element. Locating posts 119 extend from the upper surface of the body 101 adjacent the interconnect region to ensure and maintain proper positioning of the clamping plate 120 over the interconnect region.

The alignment channel 112 may be formed in the body 101 or the clamping plate 120, or the alignment channel may be formed in the body 101 and the clamping plate 120. The alignment channel 112 may have a semi-circular cross-section, a trapezoidal cross-section, a rectangular cross-section, or a V-shaped cross-section. In the embodiment of fig. 1A and 1B, the alignment groove 112 is formed in the body 101, while the clamping plate 120 has a main surface with a flat shape. The body and the clamp plate are brought together to hold the one or more optical fibers in place in the alignment groove prior to curing of the optical adhesive or mechanical clamping of the splice element. Optical adhesives that can be used with the exemplary optical splice elements described herein are described, for example, in U.S. patent publication 2018/0072924, which is incorporated herein in its entirety. For example, the optical adhesive may be an epoxy-based adhesive composition comprising non-aggregated surface-modified silica nanoparticles dispersed in an epoxy resin, the non-aggregated surface-modified silica nanoparticles being cured by exposure to blue light.

An exemplary light source for curing the adhesive compositions described herein may have about 500mW/cm²To about 3000mW/cm²And may include a conventional blue light source, such as Paradigm from 3M Company (3M Company, st. paul, MN), st^TMA deep LED curing light, or may be an LED curing array. In one exemplary aspect, the LED light source not only provides photonic initiation of the polymerization reaction, but also has sufficient energy to photonically heat the bonding region such that the adhesive reaches a higher glass transition temperature (Tg) than can be produced by photonic initiation alone. When used to bond optical fibers in an optical splice device, the higher Tg of the adhesive can result in a more stable optical splice, allowing the resulting splice connection to pass more stringent environmental stress tests.

In one exemplary aspect, the LED array will have a wavelength optimized for material curing and modification. The various form factors and features may include an LED array curing device designed as a portable handheld unit (e.g., LED light pen, LED array, etc.) to cover a target area (e.g., radial, segmented, and organic shapes). Selective control of specific LEDs in the array allows for exposure of smaller regions of material. Heat flux may be managed by large surface area heat sinks and/or forced air flow through the array.

Current methods of optical curing typically involve facing the reactive material with a large external lamp. A uniform radiation emission level may need to be about 100mW/cm²Or higher. When using LED-based light sources, the spectral width, placement and layout of the LEDs are carefully defined to provide a uniform light distribution for curing at the desired wavelength and intensity.

In one exemplary aspect, the LEDs may be arranged in a one-dimensional array, while in other aspects, the LEDs may be arranged in a two-dimensional array. In an exemplary aspect, the LEDs may be arranged in a plurality of blocks or bars, which are then configured in a two-dimensional array to allow selective exposure on a given curing area. The LEDs may be arranged in a regular array with uniform spacing (e.g., with a linear, hexagonal, or other geometric arrangement) to maximize light uniformity, minimize the number of LEDs used, or for other reasons. In one exemplary aspect, the LED array may be configured to be uniformly distributed over the area intended to be cured (plus an appropriate perimeter), from a small portion of the total area to several times the total area, to ensure uniform curing of the sample from the center to the edges.

In one aspect, an LED array curing source may be used to cure the exemplary adhesive after about 60 seconds of exposure, preferably after about 30 seconds of exposure.

The splint 120 may be a thin flexible glass splint. The clamping plate may be placed in a first or non-bent position to allow room for insertion of the optical fiber, and in a second bent or clamped position with the application of an external force that causes the flexible glass clamping plate to close any gaps or free spaces and align and secure the optical fiber in the interconnection area. In an exemplary embodiment, the optical adhesive can be irradiated to cure the adhesive, thereby permanently securing the optical fibers in the splice element 100. In one aspect, the force applied to the splint is permanent, while in other aspects the force may be released after the adhesive has cured. Fig. 2A-2C illustrate a splice connection with the splice member 100, as will be explained in detail below. In exemplary aspects, the clamping plates can be rectangular, square, circular, or other polygonal shapes as desired for a given splicing device.

In an alternative aspect, the splint may be a non-silica based flexible splint. For example, the non-silica-based flexible splint may be formed from a thin sheet of metal (such as invar or stainless steel) or include a glass-filled liquid crystal polymer material (such as that available from Ticona Engineering Polymers, Florence, KY) available from florfenicol, Florence

A130 LCP reinforced glass). In exemplary embodiments, the thickness of the sandwich plate may be between about 25 microns to about 250 microns, preferably between about 75 microns and about 125 microns.

At least one of the splice element body 101 and the clamping plate 120 is formed of a silica material, particularly a net shape cast cured silica material, as described, for example, in international publication WO 2018/044565 and U.S. publication 2018/0067262, each of which is incorporated herein in its entirety. In an alternative embodiment, the splice member body 101 and the clamp plate 120 are both formed of a net shape cast cured silica material. In an exemplary embodiment, the part made of net shape cast cured silica material is transparent. For example, a net shape cast cured silica material may have a transparency of greater than about 90% at light wavelengths between 430nm and about 480 nm. Such transparent net shape cast cured silica materials allow the use of a visible light source directed from the exterior of the structure through one of the splice member body or the clamping plate to cure the optical adhesive disposed therein. By utilizing a net shape cast cured silica alignment mechanism and an adhesive composition comprising silica nanoparticles, the temperature performance of the splice member can be stable over a wide temperature range because the thermal characteristics of the optical fiber and the splice member are substantially the same.

In some embodiments, the surface of the silica splice member 100 and/or the splint 120 may be coated with an aluminum, copper, or parylene coating (e.g., between 3 μm and 25 μm thick). Although not required, such conformable materials can be used to optimize fiber retention, fiber stress, and concentric alignment. For example, parylene is transparent, can be easily applied by evaporation, and is stable at high temperatures. For example, Parylene C, available from Specialty Coating Systems, Indianapolis, Ind, is commonly used to coat printed circuit boards and body implants.

In one exemplary aspect, the exemplary multi-fiber splicing device can be used to splice two separate multi-fiber cables as previously described, while in an alternative embodiment, the exemplary multi-fiber splicing device can be used to repair a damaged multi-fiber cable by: simply cut out the damaged portion of the cable and splice the two cable portions as if they were two discrete multi-fiber cables.

Exemplary splice elements may be provided in a structure or housing to protect the splice and/or provide eye safety or facilitate handling during use, as will be described below with reference to fig. 4 and 5A-5B. In addition, the housing may include features to facilitate fiber alignment, splice actuation, and in some embodiments, a means to allow initiation and curing of the optical coupling material.

An exemplary splicing process is illustrated in fig. 2A-2C, wherein a first fiber optic ribbon 50 including a plurality of first optical fibers 54 may be spliced to a second fiber optic ribbon (not shown) including a plurality of second optical fibers 54'. The optical fibers are oriented in a parallel planar array in the ribbon and surrounded by a ribbon jacket 52. The optical fibers in the exemplary ribbons can be standard single mode or multimode optical fibers such as SMF 28, OM2, OM3, OM4, OM5 fiber optic ribbon cable (available from Corning Inc.).

First, a portion of the ribbon sheath 52 is removed from the terminal end of the ribbon fiber 50 to expose the optical fiber 54. The protective acrylate coating on the optical fiber can be stripped to a desired length. In one aspect, the acrylate coating on the optical fiber may be stripped and cut to a length of between 2mm and 15mm, preferably about 5 mm. In one exemplary embodiment, the optical fiber can be cleaved such that the end face of the optical fiber is perpendicular to the longitudinal axis of the optical fiber (i.e., a flat cleave). In alternative embodiments, the optical fiber may be cleaved at an angle of between 2 ° and about 10 °, preferably between 4 ° and about 8 °, from perpendicular. In some embodiments, a post-cleave end trim step can be used to shape or angle the end of the optical fiber. Exemplary post-cut end trimming processes may include abrasive polishing and/or laser trimming.

The ends of optical fibers 54 of first fiber optic ribbon 50 are inserted into entrance opening 113a at first end 101a of splice element 100, as indicated by directional arrow 99 shown in FIG. 2A. The optical fiber is slid through the alignment channel 112 until the end of the optical fiber is disposed in the center of the interconnection region 105.

A second fiber optic ribbon is prepared as described above. A second optical fiber 54' (fig. 2B) of the second ribbon 50 is inserted into the entrance opening 113B at the second end 101B of the splice element 100 and slid through the corresponding alignment channel until the end of the optical fiber is disposed in the center of the interconnection zone 105 and abuts the end of the first optical fiber 54, as shown in fig. 2B and 3A. Next, as shown in fig. 2C and 3B, a force F is applied to the clamp plate 120, thereby bending a portion of the clamp plate toward the splice member 100 to close any gaps or free spaces between the clamp plate and the optical fibers and align the optical fibers in the interconnection region. The fiber ends contact in an interconnection region, wherein the fiber ends may be generally concentrically clamped when the splice element and the clamp plate are pressed together.

In an exemplary aspect, the splice element 100 can be pre-loaded with an optical adhesive (not shown) in the interconnection area. After the force is applied to the clamp plate, the optical adhesive can be irradiated with light of an appropriate wavelength to cure the adhesive, thereby permanently securing the optical fibers in the splice element 100. Once actuated, a light source (not shown), such as a conventional blue light source, can be used to provide the necessary actinic radiation through transparent splint 120 (or transparent body 101) to cure the optical adhesive.

In another embodiment, an exemplary field termination process is provided. Known peel strip tabs on the splice member and/or blister packs that are black to visible light or optically opaque may be used to protect the splice member and preloaded adhesive from dust and light exposure during shipping. The field optical fiber may use, for example, 3M^TMEasy clean, or another commercial cutter such as CI-01 provided by japan ltd (illintech, Korea) in Korea.

The field optical fiber can be inserted into the

entrance openings

113a, 113b of the splice element 100. The clamp plate 120 may be axially disposed, such as described above. A Paradigm light pen (available from 3M Company, trade number 76962) that emits blue light in the range of 430nm to 480nm, a battery-driven LED array, a wired light source, etc. may be used to cure the adhesive. A mounting tool (not shown) having a nest may be provided to align and hold the light source on the splice window area during approximately 20-30 second splice adhesive cure cycles. This type of docking operation can remove process variability, thereby ensuring that the intended exposure reaches the adhesive.

Exemplary multi-fiber devices may be used in a wide range of applications requiring low-loss optical connections, particularly when the connections are semi-permanent or permanent. In some embodiments, the exemplary multi-fiber devices may be used in fiber optic cassettes, terminations, patch panels, and the like, where splices may be located in partitions or through walls of the housing. For example, an optical box or terminal may include: a housing having a top, a bottom, and a plurality of sidewalls disposed between the top and the bottom; and an element housing disposed through one of the plurality of side walls. A multi-fiber splice component can be disposed in the component housing to interconnect the terminal ends of the plurality of external optical fibers to the plurality of terminal ends of the optical fibers disposed within the housing. In one aspect, the multi-fiber splice element can be a multi-fiber splice element similar to splice element 100 described above, wherein the multi-fiber splice element has a body with a plurality of alignment channels configured to receive a plurality of first optical fibers and a plurality of second optical fibers in an end-to-end manner; a clamp plate, wherein at least one of the body and the clamp plate is formed of a coefficient of thermal expansion matched silica material; and an optical coupling material disposed in at least a portion of the plurality of alignment channels such that the optical coupling material is positioned between the first plurality of optical fibers and the second plurality of optical fibers.

The plurality of signal paths exit the cassette or pass through one of the plurality of side walls. In some embodiments, the plurality of signal paths include connection points at the sidewalls from which the plurality of signal paths exit the cassette. The connection point may be a fiber optic connector connection point or a fiber optic splice connection point. The connection points may be configured as single fiber connection points or multi-fiber connection points. In an exemplary use, a cassette or terminal may include single fiber connection points, wherein a plurality of single fiber connector connection points are mated such that a first of the paired single fiber connection points is designated a transmit port and a second of the paired single fiber connection points is designated a receive port. In this aspect, signals carried by the plurality of external optical fibers may be reordered within the cassette or terminal such that the signals exit the cassette in a different order than they enter the cassette. In some embodiments, this reordering of signal paths is used to manage the polarity of the transmit and receive ports.

Fig. 4 shows an exemplary optical fanout box 200 having a plurality of single fiber connections 220 on one side of the box and a plug and splice interconnect system 250 on the other side of the box. In this embodiment, the plug and splice interconnect is a two-piece connection system including a plug and socket arrangement.

The optics box 200 is a housing or casing 201 having a top (not shown) and a bottom 202 and a plurality of

side walls

203, 204 disposed between the top and bottom. The housing has an internal cavity in the side wall for receiving and supporting the fan-out optical fibers. Multiple single fiber connections may be made through ports on the front side wall 204. In particular, the ports may be a plurality of single fiber connector adapters 222 mounted in the front sidewall 204. The single fiber connector adapter 222 may be any standard format connector adapter such as an LC-format connector adapter, an SC-format connector adapter, or the like. The connector adapter shown in fig. 4 is a duplex LC connector adapter.

The sidewall 203 may be a single continuous sidewall that extends from one end of the front sidewall 204 around the circumference of the housing to a second end of the front sidewall. In an exemplary aspect, the sidewall 203 can include a plurality of wall segments 203a-203 e. A multi-fiber plug and splice interconnect 250 may be disposed in the sidewall 203. In the embodiment shown in fig. 4, the plug and splice interconnect 250 is disposed in the wall section 203 c. The multi-fiber plug and splice interconnect 250 includes a multi-fiber splice device 260 (i.e., a receptacle portion of a two-piece connection system) mounted in the optical fanout box 200 and a bare multi-fiber retainer 280 (i.e., a plug portion of a two-piece connection system) that can be secured in the field in the multi-fiber splice device. In an exemplary aspect, a multi-fiber splice device can be factory assembled onto the end of a multi-fiber stub 212 and installed into the sidewall 203 of the optical fanout box 200. In exemplary aspects, the multi-fiber stub can be an array of individual fibers, a fiber optic ribbon, or a collection of individual fibers that have been ribbonized to aggregate the individual fibers into a single, easily handled configuration. In alternative embodiments, the multi-fiber plug and splice interconnect 250 can be disposed in a front sidewall (such as sidewall 204) of the cassette.

The fan-out fibers 210 may be arranged in a generally planar array or a two-dimensional array, such as a radial array or a hexagonal array. Each of the individual fanout fibers, which are terminated at one end with a fiber optic connector 225 and spliced into the multi-fiber stub 212 at its other end, are inserted into a single fiber connector adapter 222 disposed in the front wall 204 of the cassette 200. In some applications, such as those encountered in Fiber To The Home (FTTH) applications, fiber optic connectors on a given fanout fiber 210 may be routed to a port in the cassette corresponding to the location in the multi-fiber stub occupied by the fanout fiber, such that a first fanout fiber 210a occupying a first location in the multi-fiber stub is routed to a first port 222a in the optical cassette 200.

In other applications, the ports in the optical box are matched in duplex pairs. For example, in high speed data systems used in wireless and data center applications,

ports

222a and 222b may form a duplex pair. The transmit and receive fibers of a given duplex pair may not be disposed adjacent to each other in the incoming ribbon fiber cable 50. In this case, the example optical cassette may be configured such that fanout fiber 210a in a first position in the multi-fiber stub corresponds to a transmitting fiber in a first duplex pair in ribbon fiber cable 50 and may be routed to port 222a of optical cassette 200, and fanout fiber 210b in a tenth position in the multi-fiber stub corresponds to a receiving fiber in the first duplex pair in ribbon fiber cable 50 and may be routed to port 222b of the optical cassette.

One of ordinary skill in the art will recognize that fanout fibers 210 may take other alternative routes within the cassette. Further, while the cassette shown in fig. 4 is illustrated as having twelve fan-out fibers in a multi-fiber stub, multi-fiber stubs having other fiber numbers (e.g., 8 fan-out fibers, 16 fan-out fibers, 24 fan-out fibers, etc.) are also contemplated within the scope of the present disclosure. Additionally, the example cassette may include more than one plug and splice interconnect 250.

Multiple boxes may be grouped together and installed in a rack system in a data center or central office. In alternative embodiments, the cassette may be a sealed housing or terminal to provide further environmental protection.

In a first aspect, a cassette or termination according to the present invention may include a plurality of terminations of optical fibers disposed within a housing factory-mounted into a multi-fiber splice element. In a second aspect, multiple terminations of optical fibers disposed within a housing may be mounted in the field to a multi-fiber splice component of a cassette or termination. In a third aspect, all optical connections provided within an exemplary box or terminal are made at the factory and assembled into the box or terminal, thereby allowing the terminal to be sealed at the factory so that access to the interior of the box is thereafter unavailable.

The multi-fiber plug and splice interconnect 250 is configured to allow field interconnection of optical fan-out cassettes 200 in applications that do not require repeated reconfiguration. The example techniques described herein provide optical splice connection performance with the maneuverability of fiber optic connectors. In some embodiments, the exemplary multi-fiber plug and splice interconnection system may eliminate the need for field preparation of bare optical fibers, including conventional multi-fiber stripping, cleaving, cleaning, and polishing operations, which are typically required for field termination of fiber optic cables.

The multi-fiber splice device 260 of the multi-fiber plug and splice interconnect 250 includes an exemplary splice component 265 disposed within a component housing 270. Splice member 265 is generally similar to splice member 100 except that body 266 of splice member 265 has a semi-cylindrical shape as compared to the generally rectangular parallelepiped sheet shape of splice member 100. The splice member 265 includes an integral alignment mechanism that includes a plurality of alignment grooves or channels 267 extending from the first end 266a to the second end 266b of the splice body 266, wherein each alignment channel is configured to guide and support a single optical fiber.

The element housing 270 has a generally tubular shape that includes a central channel 271 extending from a first end 270a to a second end of the element housing, the central channel configured to retain and protect the splice element 266 within the channel. The component housing may include a flange 274 disposed midway along the component housing to help position the multi-fiber splice device 260 in the sidewall 203 of the optical fanout box 200. The flange abuts one side of the sidewall 203 and a retaining mechanism can be positioned on the other side of the sidewall to secure the multi-fiber splice device in the cassette. The component housing may include a mounting region between the flange and the second end of the component housing, which may be configured to receive a retaining mechanism in the form of an actuation cam. In one embodiment, the retention mechanism may be a spring clip (not shown) that may be locked into a groove (not shown) formed in a surface of the mounting region adjacent the sidewall. In alternative embodiments, the retaining mechanism may be a threaded or mechanical fastener (not shown) that may be secured to a mounting region having a threaded surface. In another alternative embodiment, the element housing may be permanently bonded in the side wall by structural adhesive or by conventional welding techniques. In yet another embodiment, the element may be integrally formed with the side wall of the cassette.

In the exemplary embodiment shown in fig. 5A, a strain relief boot 269 may be fitted over the mounting region. The mounting region may have at least one annular barb 273 or annular row of teeth configured to secure the strain relief boot to the element housing. In this embodiment, a strain-relief boot may be used as a retention mechanism to secure the multi-fiber splice device 260 in the side wall of the cassette.

As shown in fig. 5B, the multi-fiber bare fiber holder 280 of the multi-fiber plug and splice interconnect 250 retains and protects each of a plurality of prepared ends of optical fibers configured for splicing via the multi-fiber splice device 260. The plurality of optical fibers 54 from the fiber optic ribbon 50 are held (e.g., at a predetermined protrusion distance) by the multi-fiber bare fiber holder 280. An exemplary multi-fiber bare fiber holder includes: a strap anchor; an optical fiber alignment mechanism to align and protect the prepared end; and a locking mechanism to secure the bare multifiber fiber holder to the multifiber splicing device. In the exemplary embodiment shown in fig. 5B and 6A-6C, the fiber alignment mechanism can be a fiber alignment collar 295 and the locking mechanism can be a locking sleeve.

The ribbon anchor 282 has a first end 282a and a second end 282b, a locking sleeve 290 disposed over the first end of the ribbon anchor, and a spring-loaded fiber alignment collar 295 disposed within the first end of the ribbon anchor. A tension release boot 289 can be provided at the second end 282b of the ribbon anchor to provide tension release and bend control for the fiber optic ribbon 50 to enter the ribbon anchor. When the two

half shells

283a, 283b are latched together by latch arms 287 that fit into latch receptacles 288, strap anchor 282 may have a generally hollow cylindrical structure formed by the two half shells, although other generally tubular structures are possible. The housing halves include spaced apart

interior positioning walls

284a, 284b on the interior thereof that are configured to position fiber optic ribbons 50 along the centerline of the ribbon anchor. Each of the locating walls includes a slot 285 formed in a top surface thereof. The slots are sized such that when the half shells are mated together, the internal dimensions of the combined slots are only slightly larger than the ribbon fiber to be installed in the bare multi-fiber holder 280. The space between the retaining walls may be filled with a potting compound or adhesive to secure the fiber optic ribbon within the ribbon anchor.

The optical fiber alignment collar 295 can be disposed within the first end of the ribbon anchor such that it is free to slide longitudinally relative to the ribbon anchor from a first or extended position, shown in fig. 6A, to a second or retracted position, shown in fig. 6C. In a first aspect, the alignment collar may be generally cylindrical, as shown in fig. 5B. The alignment collar may have a plurality of parallel holes 296 extending therethrough. The bore is sized to be slightly larger than the optical fiber 54 to be passed therethrough and has the same pitch as the optical fiber so that the optical fiber is free to move longitudinally within the bore. A compression spring 298 is disposed in the first end of the ribbon anchor between the locating wall 284a and the fiber alignment collar.

Locking sleeve 290 is a generally cylindrical tubular member rotatably connected to the band anchor. In an exemplary aspect, the locking sleeve may include a slot extending through the locking sleeve. The slot engages a rotation control catch 286 near the first end of the strap anchor. The width of the fastener is less than the width of the slot, thereby allowing the locking sleeve to rotate a controlled amount. In exemplary aspects, the locking sleeve can be rotated about the centerline of the strap anchor by about 15 degrees to about 120 degrees, preferably about 30 degrees to about 90 degrees. The locking sleeve may secure the bare multifiber fiber holder 280 to the multifiber splicing device 260 via a bayonet connection mechanism using, for example, connection pegs 276 (fig. 5A) on the multifiber splicing device and bayonet connection slots 292 on the locking sleeve. In the alternative, the locking sleeve may secure the multi-fiber bare fiber holder 280 to the multi-fiber splice device 260 via a conventional threaded connection mechanism. In yet another alternative, the locking sleeve may secure the multi-fiber bare fiber holder 280 to the multi-fiber splice device 260 via an interference connection mechanism.

Fig. 6A-6C are a series of cross-sectional detail views illustrating interconnection of a multi-fiber bare fiber holder 280 with a multi-fiber splice device 260 disposed in a sidewall 203 of cassette 200 to form a multi-fiber plug and splice interconnect 250. FIG. 6A shows the multi-fiber bare fiber holder and multi-fiber splicing device in a fully disconnected state, with the fiber alignment collar 295 disposed in its forward position in the locking sleeve 290, thereby protecting the end of the cleaved bare fiber end (not shown). The bare fiber holder is moved toward the cassette 200 as indicated by directional arrow 299a until the front face of the fiber alignment collar 295 abuts the second end of the element housing 270, as shown in FIG. 6B. As the multi-fiber bare fiber holder continues to move toward cassette 200 as indicated by directional arrow 299a, the fibers emerge through the holes in the alignment collar, entering the alignment passage of splice element 265. After the optical fiber is fully inserted into the alignment channel, the bare fiber holder may be locked in place by rotating the locking sleeve to engage the bayonet coupling mechanism. Fig. 6C shows the multi-fiber bare fiber holder 280 fully engaged with the multi-fiber splicing device 260 such that the fiber alignment sleeve 295 is disposed adjacent the end of the ribbon anchor 282.

In an alternative embodiment, the multi-fiber plug and splice interconnect 250 can be used without the cassette housing 201 to manufacture a fiber bundle assembly. For example, multi-fiber plug and splice interconnect 250 can be used to directly connect a fanout section to a continuous transmission section including optical fiber ribbons 50 using multi-fiber splice device 260 and bare multi-fiber retainer 280 that can be fixed in the multi-fiber splice device in the field or at the factory. This may be particularly advantageous when the fan-out section is made in a first position, the transfer section is made in a second position and the fan-out section to the successive transfer section are put together in a third position.

In some exemplary embodiments where a permanent final connection is desired, the optical fibers held by the bare fiber holders 260 may be secured in the splice element 265 by an adhesive. The adhesive may be a two-part epoxy adhesive, an anaerobic adhesive, or a light curable adhesive. When the adhesive used is a light-curing adhesive, the element case should be made of a material transparent to the wavelength of light used to cure the adhesive. In some aspects, the splice element may also be transparent to the wavelength of light used to cure the adhesive.

The exemplary multi-fiber splicing devices and multi-fiber splice connection systems described herein provide fusion-like properties without fusion splicing and, therefore, without the need for expensive or elaborate optical fusion splicers. Such fusion machines require a source of electrical power, time to heat to shrink the protective sleeve, and are delicate instruments that can be easily damaged if dropped.

An exemplary connection made in accordance with the present disclosure should have an insertion loss of less than 0.1dB, a return loss variation of less than 10dB when temperature is cycled from-40 ℃ to 75 ℃, and a pullout strength of greater than 0.5 lbf/fiber.

List of embodiments

Embodiment 1A is a multi-fiber splicing device for splicing a plurality of first optical fibers and a plurality of second optical fibers. A multi-fiber splicing device includes: a multi-fiber splice element having a body with a plurality of alignment channels configured to receive a plurality of first optical fibers and a plurality of second optical fibers in an end-to-end manner, wherein each of the first plurality of alignment channels has an arcuate profile; a clamp plate, wherein at least one of the body and the clamp plate is formed of a low coefficient of thermal expansion silica material, and an optical coupling material is disposed in at least a portion of the plurality of alignment channels such that the optical coupling material is positioned between the first plurality of optical fibers and the second plurality of optical fibers.

Embodiment 2A is the multi-fiber splicing device of embodiment 1A wherein the optical coupling material is at least one of an index matching material or an optical adhesive.

Embodiment 3A is the multi-fiber splice device of embodiment 2A, wherein the optical adhesive is curable via actinic radiation to form a durable multi-fiber optical splice.

Embodiment 4A is the multi-fiber splicing device of any one of embodiments 2A or 3A wherein the optical adhesive is blue light curable.

Embodiment 5A is the multi-fiber splicing device of any one of embodiments 2A-4A wherein the optical adhesive comprises an adhesive composition comprising non-aggregated, surface-modified silica nanoparticles dispersed in an epoxy resin.

Embodiment 6A is the multi-fiber splicing device of any preceding embodiment, wherein the body comprises a first plurality of alignment channels formed on a major surface thereof.

Embodiment 7A is the multi-fiber splicing device of embodiment 1A wherein the arcuate profile includes a generally planar portion at the entrance opening at either end of an alignment channel that rises slowly between the entrance opening and an interconnection region centrally located on the body, and wherein the alignment channel culminates in a shallow dome within the interconnection region.

Embodiment 8A is the multi-fiber splicing device of any preceding embodiment, wherein the clamping plate is a thin, flexible glass clamping plate that is bent to align and secure the terminal ends of the plurality of first optical fibers and the plurality of second optical fibers in the interconnection region of the multi-fiber splicing element.

Embodiment 9A is the multi-fiber splicing apparatus of any preceding embodiment further comprising means for applying a compressive force on the clamping plate that flexes the clamping plate to align and secure the terminal ends of the plurality of first optical fibers and the plurality of second optical fibers in the alignment channel in the interconnection region of the multi-fiber splicing element.

Embodiment 10A is the multi-fiber splicing apparatus of embodiment 9A wherein the means for applying a compressive force comprises a spring clip.

Embodiment 11A is the multi-fiber splicing apparatus of embodiment 10A wherein the means for applying a compressive force comprises an activation cam.

Embodiment 12A is the multi-fiber splicing device of any preceding embodiment, wherein the body has a generally rectangular shape.

Embodiment 13A is the multi-fiber splicing device of any preceding embodiment, wherein the body has a generally semi-cylindrical shape.

Embodiment 14A is the multi-fiber splicing device of any preceding embodiment, wherein the substrate further comprises funnel-shaped entrance openings at both ends of the alignment groove, wherein the entrance openings are wider than the alignment groove.

Embodiment 15A is the multi-fiber splicing device of any preceding embodiment, wherein the plurality of alignment channels are parallel and spaced apart from each other on a major surface of the splicing element.

Embodiment 16A is the multi-fiber splicing device of any preceding embodiment, wherein the fiber splice experiences an insertion loss of less than 0.1 dB.

Embodiment 17A is the multi-fiber splice device of any preceding embodiment, wherein the multi-fiber splice has a return loss variation of less than 10dB when the temperature is cycled from-40 ℃ to +75 ℃.

Embodiment 18A is the multi-fiber splicing apparatus of any preceding embodiment, wherein the multi-fiber splice has a pullout strength (pullout strength) of greater than 0.5 lbf/fiber.

Embodiment 19A is the multi-fiber splicing device of any preceding embodiment, wherein the silica material is a net-shape cast cured silica material.

Embodiment 20A is a multi-fiber ribbon repair device comprising the splice device of any of the preceding embodiments.

Embodiment 21A is a multi-fiber ribbon fanout box comprising the splicing device of any of the preceding embodiments.

Embodiment 1B is an optical cartridge comprising: a housing having a top, a bottom, and a plurality of sidewalls disposed between the top and the bottom; and an element housing disposed through one of the plurality of side walls. A multi-fiber splice element disposed in the element housing to interconnect the terminal ends of the plurality of external optical fibers to the plurality of terminal ends of the optical fibers disposed within the housing, wherein the multi-fiber splice element has a body with a plurality of alignment channels configured to receive the plurality of first optical fibers and the plurality of second optical fibers in an end-to-end manner; a clamp plate, wherein at least one of the body and the clamp plate is formed of a coefficient of thermal expansion matched silica material; and an optical coupling material disposed in at least a portion of the plurality of alignment channels such that the optical coupling material is positioned between the first plurality of optical fibers and the second plurality of optical fibers.

Embodiment 2B is the cassette of embodiment 1B, further comprising an optical coupling material disposed in at least a portion of the plurality of alignment channels such that the optical coupling material is positioned between the first plurality of optical fibers and the second plurality of optical fibers.

Embodiment 3B is the cartridge of any one of embodiments 1B or 2B, further comprising a plurality of signal paths exiting through one of the plurality of sidewalls.

Embodiment 4B is the cartridge of embodiment 3B, wherein each of the plurality of signal paths includes a connection point at the sidewall from which the plurality of signal paths exit the cartridge.

Embodiment 5B is the cartridge of embodiment 4B, wherein the connection points comprise fiber optic connector connection points.

Embodiment 6B is the cartridge of embodiment 5B, wherein the fiber optic connector connection points are multi-fiber connector connection points.

Embodiment 7B is the cartridge of embodiment 6B, wherein the fiber optic connector connection points comprise a plurality of single fiber connector connection points.

Embodiment 8B is the cassette of embodiment 7B, wherein the plurality of single fiber connector connection points are mated, wherein a first of the paired single fiber connection points is designated as a transmit port and a second of the paired single fiber connection points is designated as a receive port.

Embodiment 9B is the cassette of embodiment 4B, wherein the connection points comprise fiber optic splice connection points.

Embodiment 10B is the cassette of embodiment 9B, wherein the fiber optic connector connection points are multi-fiber splice connection points.

Embodiment 11B is the cartridge of embodiment 9B, wherein the fiber optic connector connection points comprise a plurality of single fiber connector connection points.

Embodiment 12B is the cassette of any of embodiments 1B-11B, wherein signals carried by the plurality of external optical fibers are reordered within the cassette such that the signals exit the cassette in a different order than they entered the cassette.

Embodiment 13B is the cassette of embodiment 12B, wherein the optical fibers are reordered to manage the polarity of the signals exiting the cassette.

Embodiment 14B is the cassette of any of embodiments 1B-13B, wherein the plurality of terminations of the optical fibers disposed within the housing are factory installed into the multi-fiber splice element.

Embodiment 15B is the cassette of any of embodiments 1B-13B, wherein the plurality of terminations of the optical fibers disposed within the housing are installed into the multi-fiber splice element in the field.

Embodiment 16B is the cartridge of any one of embodiments 1B-13B, wherein all optical connections within the cartridge are completed and the cartridge is assembled at a factory such that access to the cartridge interior is thereafter unavailable.

Embodiment 1C is a method of splicing a plurality of first optical fibers to a plurality of second optical fibers, comprising: inserting a first plurality of optical fibers into a plurality of alignment channels formed in a multi-fiber silica splice element, wherein the plurality of alignment channels are configured to receive the first plurality of optical fibers and the second plurality of optical fibers in an end-to-end manner; inserting a second plurality of optical fibers into the plurality of alignment channels such that the terminal ends of the first plurality of optical fibers are in close proximity to the ends of the second plurality of optical fibers; and applying a compressive force on the flexible clamping plate to bend the clamping plate to align and secure the terminal ends of the plurality of first optical fibers and the plurality of second optical fibers in the alignment channels in the interconnection region of the multi-fiber splice component.

Embodiment 2C is the method of embodiment 1C, further comprising the steps of: curing the optical adhesive disposed in the plurality of alignment channels by directing an effective amount of actinic radiation toward the optical adhesive.

Embodiment 3C is the method of embodiment 2C, wherein the curing step comprises directing an effective amount of blue light through at least one of the plates toward the optical adhesive.

Embodiment 1D is a multi-fiber splicing apparatus for splicing a plurality of first optical fibers and a plurality of second optical fibers. A multi-fiber splicing device includes: a multi-fiber splicing element having a body with a plurality of alignment channels configured to receive a plurality of first optical fibers and a plurality of second optical fibers in an end-to-end manner; a clamp plate, wherein the clamp plate is a thin flexible glass clamp plate that is bent to align and secure the terminal ends of the first and second plurality of optical fibers in the interconnection region of the multi-fiber splicing element; wherein at least one of the body and the clamp plate is formed of a low coefficient of thermal expansion silica material and an optical coupling material is disposed in at least a portion of the plurality of alignment channels such that the optical coupling material is positioned between the first plurality of optical fibers and the second plurality of optical fibers.

Embodiment 2D is the multi-fiber splicing device of embodiment 1D, wherein the optical coupling material is at least one of an index matching material or an optical adhesive.

Embodiment 3D is the multi-fiber splicing apparatus of embodiment 2D, wherein the optical adhesive is curable via actinic radiation to form a durable multi-fiber optical splice.

Embodiment 4D is the multi-fiber splicing device of any one of embodiments 2D or 3D, wherein the optical adhesive is blue light curable.

Embodiment 5D is the multi-fiber splicing device of any one of embodiments 2D-4D wherein the optical adhesive comprises an adhesive composition comprising non-aggregated, surface-modified silica nanoparticles dispersed in an epoxy resin.

Embodiment 6D is the multi-fiber splicing device of any preceding embodiment, wherein the body comprises a first plurality of alignment channels formed on a major surface thereof.

Embodiment 7D is the multi-fiber splicing device of any preceding embodiment, wherein each of the first plurality of alignment channels has an arcuate profile.

Embodiment 8D is the multi-fiber splicing device of embodiment 7D wherein the arcuate profile includes a generally planar portion at the entrance opening at either end of the alignment channel, the alignment channel slowly ascending between the entrance opening and an interconnection region centrally located on the body, and wherein the alignment channel culminates in a shallow dome within the interconnection region.

Embodiment 9D is the multi-fiber splicing apparatus of any preceding embodiment further comprising means for applying a compressive force on the clamping plate that flexes the clamping plate to align and secure the terminal ends of the plurality of first optical fibers and the plurality of second optical fibers in the alignment channel in the interconnection region of the multi-fiber splicing element.

Embodiment 10D is the multi-fiber splicing apparatus of embodiment 9D, wherein the means for applying a compressive force comprises a spring clip.

Embodiment 11D is the multi-fiber splicing apparatus of embodiment 9D wherein the means for applying a compressive force comprises an activation cam.

Embodiment 12D is the multi-fiber splicing device of any preceding embodiment, wherein the body has a generally rectangular shape.

Embodiment 13D is the multi-fiber splicing device of any preceding embodiment, wherein the body has a generally semi-cylindrical shape.

Embodiment 14D is the multi-fiber splicing device of any preceding embodiment, wherein the substrate further comprises funnel-shaped entrance openings at both ends of the alignment groove, wherein the entrance openings are wider than the alignment groove.

Embodiment 15D is the multi-fiber splicing device of any preceding embodiment, wherein the plurality of alignment channels are parallel and spaced apart from each other on a major surface of the splicing element.

Embodiment 16D is the multi-fiber splicing device of any preceding embodiment, wherein the fiber splice experiences an insertion loss of less than 0.1 dB.

Embodiment 17D is the multi-fiber splicing device of any preceding embodiment, wherein the multi-fiber splice has a return loss variation of less than 10dB when the temperature is cycled from-40 ℃ to +75 ℃.

Embodiment 18D is the multi-fiber splicing device of any preceding embodiment, wherein the multi-fiber splice has a pullout strength greater than 0.5 lbf/fiber.

Embodiment 19D is the multi-fiber splicing device of any preceding embodiment, wherein the silica material is a net-shape cast cured silica material.

Embodiment 20D is a multi-fiber ribbon repair device comprising the splice device of any of the preceding embodiments.

Embodiment 21D is a multi-fiber ribbon fanout box comprising the splicing device of any of the preceding embodiments.

Embodiment 1E is a plug and splice interconnection system, comprising: a multi-fiber splicing device including a component housing and a multi-fiber splicing element disposed in the component housing to interconnect terminal ends of optical fibers of a pair of optical fiber ribbons, wherein the multi-fiber splicing element has a body with a plurality of alignment channels configured to receive a plurality of first optical fibers and a plurality of second optical fibers in an end-to-end manner; a clamp plate, wherein at least one of the body and the clamp plate is formed of a low coefficient of thermal expansion silica material; and a bare multifiber fiber holder that receives a prepared end of an optical fiber from one of the pair of ribbons, wherein the prepared end is introduced into the alignment channel of the multifiber splicing element when the bare multifiber fiber holder is connected to the multifiber splicing device.

Embodiment 2E is the interconnection system of embodiment 1E, wherein the multi-fiber splicing device, wherein the clamp plate is a thin flexible glass clamp plate that is bent to align and secure the terminal ends of the optical fibers in the interconnection region of the multi-fiber splicing element.

Embodiment 3E is the interconnect system of any of embodiments 1E or 2E, wherein the plurality of alignment channels have an arcuate profile.

Embodiment 4E is the interconnect system of any of embodiments 1E-3E, wherein at least one of the body and the clip is formed from a low coefficient of thermal expansion silica material.

Embodiment 5E is the interconnect system device of any one of embodiments 1E-4E, wherein the silica material is a net shape cast cured silica material.

Embodiment 6E is the interconnect system device of any one of embodiments 1E-4E, wherein the multi-fiber bare fiber holder comprises: a strap anchor; an optical fiber alignment mechanism to align and protect a prepared end of an optical fiber from one of a pair of optical fiber ribbons; and a locking mechanism to secure the bare multifiber fiber holder to the multifiber splicing device.

Embodiment 7E is the interconnection system apparatus of embodiment 6E, wherein the fiber alignment mechanism is a fiber alignment collar slidably mounted in the multi-fiber bare fiber holder.

Embodiment 8E is the interconnection system apparatus of embodiment 7E, wherein the optical fiber alignment collar is free to slide longitudinally relative to the ribbon anchor from a first or extended position to protect a prepared end of an optical fiber from one of the pair of optical fiber ribbons to a retracted position that exposes the prepared end so that the prepared end can be inserted into the alignment channel of the multi-fiber splice element.

Embodiment 9E is the interconnection system device of any of embodiments 6E-8E, wherein the locking mechanism is a locking sleeve configured to connect to a component housing of the multi-fiber splice device.

Embodiment 10E is the interconnection system device of any of embodiments 6E-8E, the locking mechanism being a locking sleeve configured to connect to a component housing of the multi-fiber splicing device via a bayonet connection mechanism.

Embodiment 11E is the interconnection system of any of embodiments 1E-10E, further comprising an optical coupling material disposed in at least a portion of the plurality of alignment channels such that the optical coupling material is positioned between the first plurality of optical fibers and the second plurality of optical fibers.

Embodiment 12E is the interconnection system of any of embodiments 1E-11E, wherein one of the pair of fiber optic ribbons includes a fan-out portion and the other of the pair of fiber optic ribbons includes a transmission portion.

Embodiment 13E is the interconnection system of embodiment 12E, wherein the terminations of the optical fibers of the fanout section are factory installed into the alignment channels of the multi-fiber splice component.

Embodiment 14E is the interconnection system of embodiment 12E, wherein the terminal ends of the optical fibers of the transmission section are factory installed into the multi-fiber bare fiber holder.

Embodiment 15E is the interconnection system of embodiment 12E, wherein the terminal ends of the optical fibers of the transmission section are factory installed into the alignment channels of the multi-fiber splice element.

Embodiment 16E is the interconnection system of embodiment 12E, wherein the terminations of the optical fibers of the fanout section are factory installed into the multi-fiber bare fiber holder.

Embodiment 17E is the interconnection system of any of embodiments 12E-16E, wherein the connection of the multi-fiber splice device and the multi-fiber bare fiber holder forms a fiber bundle assembly.

Embodiment 18E is the interconnection system of any of embodiments 1E-17E, wherein the connection of the multi-fiber splice device and the multi-fiber bare fiber holder is at least partially disposed in a sidewall of the housing to form a fanout box.

Embodiment 19E is the interconnection system of any of embodiments 1E-18E, wherein the multi-fiber splice device and the multi-fiber bare fiber holder are connected in the field.

Embodiment 20E is the interconnection system of any of embodiments 1E-18E, wherein the multi-fiber splice device and the multi-fiber bare fiber holder are factory connected.

Various modifications, equivalent processes, as well as numerous structures to which the present invention may be applicable will be readily apparent to those of skill in the art to which the present invention is directed upon review of the present specification.

Claims

1. A multi-fiber splicing device for splicing a plurality of first optical fibers and a plurality of second optical fibers, comprising:

a multi-fiber splice element having a body with a plurality of alignment channels configured to receive the plurality of first optical fibers and the plurality of second optical fibers in an end-to-end manner, wherein the plurality of alignment channels have an arcuate profile;

a splint;

wherein at least one of the body and clamp plate is formed of a low coefficient of thermal expansion silica material; and is

An optical coupling material is disposed in at least a portion of the plurality of alignment channels such that the optical coupling material is positioned between the first plurality of optical fibers and the second plurality of optical fibers.

2. The multi-fiber splicing device of claim 1, wherein the optical coupling material is at least one of an index matching material or an optical adhesive.

3. The multi-fiber splicing arrangement of claim 2 wherein the optical adhesive is curable via actinic radiation to form a durable multi-fiber optical splice.

4. The multi-fiber splicing device of claim 2 wherein the optical adhesive comprises an adhesive composition comprising non-aggregated surface-modified silica nanoparticles dispersed in an epoxy resin.

5. The multi-fiber splicing device of claim 1 wherein the body includes a first plurality of alignment channels formed on a major surface thereof.

6. The multi-fiber splicing apparatus of claim 1 wherein the clamp plate is a thin flexible glass clamp plate that is bent to align and secure the terminal ends of the first and second plurality of optical fibers in the interconnection area of the multi-fiber splicing element.

7. The multi-fiber splicing apparatus of claim 1 further comprising means for applying a compressive force on the clamping plate, the means for bending the clamping plate to align and secure the terminal ends of the first and second plurality of optical fibers in the alignment channel in the interconnection region of the multi-fiber splicing element.

8. The multi-fiber splicing device of claim 7 wherein the means for applying a compressive force comprises a spring clip.

9. The multi-fiber splicing device of claim 7 wherein the means for applying a compressive force comprises an activation cam.

10. The multi-fiber splicing device of claim 1, wherein the substrate further comprises funnel-shaped entrance openings at both ends of the alignment groove, wherein the entrance openings are wider than the alignment groove.

11. The multi-fiber splicing device of claim 1 wherein the plurality of alignment channels are parallel and spaced apart from each other on a major surface of the splicing element.

12. The multi-fiber splicing device of claim 1, wherein the fiber splice experiences an insertion loss of less than 0.1 dB.

13. The multi-fiber splicing device of claim 1, wherein the multi-fiber splice has a return loss variation of less than 10dB when temperature is cycled from-40 ℃ to +75 ℃.

14. The multi-fiber splicing device of claim 1, wherein the multi-fiber splice has a pullout strength greater than 0.5 lbf/fiber.

15. The multi-fiber splicing device of claim 1, wherein the silica material is a net-shape cast cured silica material.