GB2081468A - Manufacture of channelled ceramic elements - Google Patents
Manufacture of channelled ceramic elements Download PDFInfo
- Publication number
- GB2081468A GB2081468A GB8122209A GB8122209A GB2081468A GB 2081468 A GB2081468 A GB 2081468A GB 8122209 A GB8122209 A GB 8122209A GB 8122209 A GB8122209 A GB 8122209A GB 2081468 A GB2081468 A GB 2081468A
- Authority
- GB
- United Kingdom
- Prior art keywords
- fibre
- fibres
- ceramic
- silica
- channelled
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Classifications
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/24—Coupling light guides
- G02B6/255—Splicing of light guides, e.g. by fusion or bonding
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/24—Coupling light guides
- G02B6/26—Optical coupling means
- G02B6/28—Optical coupling means having data bus means, i.e. plural waveguides interconnected and providing an inherently bidirectional system by mixing and splitting signals
- G02B6/2804—Optical coupling means having data bus means, i.e. plural waveguides interconnected and providing an inherently bidirectional system by mixing and splitting signals forming multipart couplers without wavelength selective elements, e.g. "T" couplers, star couplers
- G02B6/2821—Optical coupling means having data bus means, i.e. plural waveguides interconnected and providing an inherently bidirectional system by mixing and splitting signals forming multipart couplers without wavelength selective elements, e.g. "T" couplers, star couplers using lateral coupling between contiguous fibres to split or combine optical signals
- G02B6/2826—Optical coupling means having data bus means, i.e. plural waveguides interconnected and providing an inherently bidirectional system by mixing and splitting signals forming multipart couplers without wavelength selective elements, e.g. "T" couplers, star couplers using lateral coupling between contiguous fibres to split or combine optical signals using mechanical machining means for shaping of the couplers, e.g. grinding or polishing
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/24—Coupling light guides
- G02B6/36—Mechanical coupling means
- G02B6/3628—Mechanical coupling means for mounting fibres to supporting carriers
- G02B6/3632—Mechanical coupling means for mounting fibres to supporting carriers characterised by the cross-sectional shape of the mechanical coupling means
- G02B6/3636—Mechanical coupling means for mounting fibres to supporting carriers characterised by the cross-sectional shape of the mechanical coupling means the mechanical coupling means being grooves
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/24—Coupling light guides
- G02B6/36—Mechanical coupling means
- G02B6/38—Mechanical coupling means having fibre to fibre mating means
- G02B6/3807—Dismountable connectors, i.e. comprising plugs
- G02B6/3873—Connectors using guide surfaces for aligning ferrule ends, e.g. tubes, sleeves, V-grooves, rods, pins, balls
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/24—Coupling light guides
- G02B6/36—Mechanical coupling means
- G02B6/38—Mechanical coupling means having fibre to fibre mating means
- G02B6/3807—Dismountable connectors, i.e. comprising plugs
- G02B6/3873—Connectors using guide surfaces for aligning ferrule ends, e.g. tubes, sleeves, V-grooves, rods, pins, balls
- G02B6/3881—Connectors using guide surfaces for aligning ferrule ends, e.g. tubes, sleeves, V-grooves, rods, pins, balls using grooves to align ferrule ends
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/24—Coupling light guides
- G02B6/36—Mechanical coupling means
- G02B6/3628—Mechanical coupling means for mounting fibres to supporting carriers
- G02B6/3632—Mechanical coupling means for mounting fibres to supporting carriers characterised by the cross-sectional shape of the mechanical coupling means
- G02B6/3644—Mechanical coupling means for mounting fibres to supporting carriers characterised by the cross-sectional shape of the mechanical coupling means the coupling means being through-holes or wall apertures
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/24—Coupling light guides
- G02B6/36—Mechanical coupling means
- G02B6/3628—Mechanical coupling means for mounting fibres to supporting carriers
- G02B6/3684—Mechanical coupling means for mounting fibres to supporting carriers characterised by the manufacturing process of surface profiling of the supporting carrier
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/24—Coupling light guides
- G02B6/36—Mechanical coupling means
- G02B6/38—Mechanical coupling means having fibre to fibre mating means
- G02B6/3807—Dismountable connectors, i.e. comprising plugs
- G02B6/381—Dismountable connectors, i.e. comprising plugs of the ferrule type, e.g. fibre ends embedded in ferrules, connecting a pair of fibres
- G02B6/3825—Dismountable connectors, i.e. comprising plugs of the ferrule type, e.g. fibre ends embedded in ferrules, connecting a pair of fibres with an intermediate part, e.g. adapter, receptacle, linking two plugs
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/24—Coupling light guides
- G02B6/36—Mechanical coupling means
- G02B6/38—Mechanical coupling means having fibre to fibre mating means
- G02B6/3807—Dismountable connectors, i.e. comprising plugs
- G02B6/3833—Details of mounting fibres in ferrules; Assembly methods; Manufacture
- G02B6/3854—Ferrules characterised by materials
Abstract
A channelled ceramic element 1, in particular for forming an optical fibre termination or connector, is produced by embedding one or more lengths of silica fibre, preferably coated with resin, in a body of powdered ceramic material which is non-silica-based, in a suitably shaped die, pressing the powder, and sintering the pressed compact: during sintering, the resin coating of the fibre or fibres (if present) is burnt off, and the silica of each fibre reacts with or is absorbed by the surrounding ceramic material, to leave a smooth-walled channel into which an optical fibre to be terminated, or pairs of optical fibres 6,7 to be spliced can be inserted. Suitable ceramic materials are alkaline earth metal titanates and zirconates. Methods for manufacturing a rectangular connector block for a plurality of pairs of fibres, a ferrule for terminating a single fibre, and connectors for coupling single fibres end-to-end and laterally, are described. <IMAGE>
Description
SPECIFICATION
Manufacture of channelled ceramic elements
This invention relates to the manufacture of channelled ceramic elements which are suitable for use, in particular but not exclusively, for forming optical fibre terminations and connector members. The invention also relates to optical fibre terminations and connectors consisting of or including channelled ceramic elements manufactured by the method described.
According to the invention, a method of manufacturing a channelled ceramic element includes the steps of embedding one or more lengths of fibre composed of silica, with or without a coating of synthetic resin, in a body of powdered ceramic material which is of a non-silica-based composition and can be sintered at a temperature not iower than 1 300 C, pressing the powder to form a selfsupporting compact surrounding the fibre of fibres, and heating the assembly of the compact and fibre or fibres at a sufficiently high temperature and for a sufficient length of time to effect sintering of the compact and to cause the silica of the fibre or fibres to be absorbed by the surrounding ceramic material, so as to leave a channel or channels in the sintered ceramic material.
Suitable ceramic materials for use in the method of the invention include, for example, alkaline earth metal titanates and zirconates, and combinations of two or more such compounds, with or without minor proportions of additives.
During the sintering step, the silica of each fibre embedded in the compact reacts with, or is otherwise absorbed by, the ceramic material, to leave a smooth-walled channel the diameter of which is determined by the diameter of the originai fibre and by the sintering characteristics of the ceramic material, in particular the amount of shrinkage of the ceramic occurring during sintering. If the silica fibre or fibres used for forming the channel or channels are resin-coated, as is preferred since such a coating renders the fibres easier to handle, the resin is burnt off. or vaporised at an early stage during the sintering process.
The method of the invention enables one or more channels of very small diameter, and of any length required, to be formed in a ceramic element, which element can be formed in any desired shape and dimensions by pressing the ceramic powder in a suitable die.
The channelled ceramic elements so produced are particularly advantageous for use as optical fibre terminations or as connector members for coupling one or more pairs of optical fibres together. However, channelled ceramic elements produced by the method of the invention are also suitable for other applications, for example for providing insulated channels for fine wires, for channelling gases or liquids between specific locations, and for gas diffusion.
The channels formed may be straight or of any other desired configuration, for example curved or undulating. Thus an optical fibre termination or butt connection can be made by inserting a fibre, or a pair of fibres in endto end relationship, into a straight channel.
Alternatively, elements having curved channels may be employed for lateral coupling of optical fibres: thus a pair of curved channels may be formed in a single element so as to meet tangentially, or two separate elements each having a curved channel may be employed, part of the ceramic of each element being removed, after insertion of optical fibres into the respective channels, to expose parts of the fibre cores so that the fibres can be coupled laterally by suitably positioning the elements in contact with one another.
For the manufacture of ceramic elements for use in the optical fibre applications referred to above, the silica fibre or fibres employed for forming the channel or channels is or are preferably of the same diameter as the optical fibre or fibres to be inserted into the channel or channels for termination or connection, and preferably also the sintering properties of the ceramic material are such that each channel formed has substantially the same diameter as the fibre employed for forming it, so that each optical fibre is a sliding fit within a channel, and when an end-to-end coupling is formed the pair of fibres are accurately coaxially aligned.
To form a termination for a single optical fibre, the ceramic element may consitute a ferrule with an axial channel, and may be profiled externally, if desired, to enable it to be fitted into a connecting sleeve or other connector member. Similarly an element for forming an end-to-end coupling between a single pair of optical fibres may be of elongate shape with an axial channel. For terminating a plurality of optical fibres, or for providing endto-end connection for a plurality of pairs of fibres, the ceramic element is conveniently formed as a rectangular block with a plurality of parallel channels there-through, arranged in one or more layers.
The shape of the sintered ceramic element may, if desired, be modified by machining.
For example, one or both of the ends of a rectangular block in which the openings of the channels are located may be chamfered to provide enlarged, sloping openings, to facilitate the insertion of optical fibres into the channels. Furthermore, when the channels are to be used for forming end-to-end optical fibre couplings, a groove may be cut across the top of the block, orthogonal to, and down to at least the level of, the channels, to permit access to the butting fibre ends and thus
facilitate the splicing operation, enabling the
fibre ends to be cleaned if necessary, and
enabling index-matching liquid or adhesive to
be introduced between the fibre ends.
Some specific forms of optical fibre terminations and connectors comprising channelled
ceramic elements manufactured by the
method of the invention are shown in the
accompanying diagrammatic drawings, and
will now be described by way of example, together with the methods employed for their
manufacture. In the drawings,
Figure 1 is a perspective view of a connector member for a plurality of optical fibre
pairs,
Figure 2 shows a termination for a single optical fibre, in sectional elevation,
Figure 3 illustrates a method of forming a
matched pair of optical fibre terminations,
Figure 4 is a perspective view of a demountable connector for a pair of optical fibres,
Figure 5 shows a branching optical coupler element in sectional elevation, and
Figure 6 is a section drawn on the line
VI-VI in Fig. 5.
The connector member shown in Fig. 1 consists of a rectangular ceramic block 1, in which nine parallel channels 2 have been formed by the method of the invention. The ends 3 of the block are chamfered to form enlarged apertures 4 at the ends of the channels, and a transverse groove 5 extends from the upper surface of the block to just below the level of the channels.
To produce the channelled block a rectangular die is half filled with powdered ceramic material, then nine resin-coated silica fibres are laid on the surface of the powder, equally spaced apart, and are covered with a further quantity of the ceramic powder to a depth equal to that below the fibres, the powder is then pressed to form a compact, and the compact is sintered. In a specific example, the ceramic material used is a barium strontium zirconate doped with small proportions of titanium oxide and tantalum oxide, and a tungsten carbide die is employed. The silica fibres are coated with polyurethane resin, and have an overall diameter of 1 50 microns.The powder is compacted under a pressure of 77.2 megapascals, and the compact is sintered by heating for one hour at 1 480'C in air, to produce a block 25 mm by 35 mm in area and 5 mm thick. During the sintering, the fibres are completely destroyed, the resin burning off and the silica combining with the ceramic material; the shrinkage of the ceramic which occurs is apparently compensated, in the vicinity of the channels formed, by migration of material away from the channels, so that the latter finally have the same diameter as the original fibres. The chamfered ends 3 of the block and the groove 5 are finally formed by machining.
In use of the connector member so formed, two sets of resin coated silica optical fibres 6,
7, each of 1 50 microns diameter, are inserted into the channels from the the respective ends of the ceramic block, so that their ends abut in the groove 5 as shown, and a liquid adhesive having a refractive index matching that of the silica fibres, such as epoxy or silicone resin, is introduced into the groove to fix the fibre ends in position and provide optical continuity between the two fibres of each abutting pair.
Fig. 2 shows a termination for a single optical fibre 8, in the form of a ceramic ferrule 9 with a channel 10 along its axis, which is produced in the same manner as the connector block described above with reference to
Fig. 1, using an appropriately shaped die and a single polyurethanecoated silica fibre placed along the longitudinal axis of the body of ceramic powder.
Referring to Fig. 3, for the manufacture of a matched pair of optical fibre terminations, an elongate double-ended ferrule 11, for example of a shape corresponding to a butted pair of ferrules of the form shown in Fig. 2, is produced by the method described above with reference to Fig. 1. A length of optical fibre 12, for example one metre long, is passed through the axial channel in the ferrule, the ferrule is bonded to the central portion of the fibre length, and then the ferrule and fibre length are cut in half, at 1 3, thus forming an identical pair of "pig-tailed" fibre connectors.
This technique is especially suitable for use with monomode optical fibres having a core diameter of, for example, 5 microns: the silica fibre employed for forming the ferrule channel will therefore be of correspondingly small diameter.
The demountable optical fibre connector shown in Fig. 4 includes a mating pair of ferrules 14, 15, the cross-section of each of which is a rectangle with one corner cut off to form a flat face 16, 1 7. The ferrules are formed by the method described with reference to Fig. 1, each with an axial channel, into which an optical fibre 18, 1 9 is inserted and bonded. The ferrules are supported in a
V-groove 20 in a metal or ceramic block 21, the reference planes 22, 23 of each ferrule fitting exactly into the V-groove, so that when the mating ends of the ferrules are brought into contact the fibre ends are accurately aligned and coupled togethei at 24. A force for retaining the ferrules in position in the Vgroove is applied to the faces 16 and 17 by spring means (not shown).
The branching coupler element shown in
Figs. 5 and 6, which is also formed by the method described with reference to Fig. 1, consists of a ceramic block 25 with a curved channel 26, through which a silica-based optical fibre consisting of a core 27 and cladding 28 is inserted. To enable the fibre to be coupled laterally, either to another fibre incor porated in a similar ceramic element, or to a photodiode or other device, the portion 29 of the ceramic block is removed, together with a portion of the fibre cladding, by lapping and polishing down to the level of the broken line 30, so as to expose a portion of the fibre core and cladding at the surface of the element, as shown in Fig. 6. The power fraction coupled can be controlled by adjusting the curvature of the channel and hence of the fibre, and the exposed area of the fibre core.
For the manufacture of the channelled ceramic elements described above with reference to Figs. 2, 3, 4, 5 and 6, the ceramic material, die material, and pressing and sintering conditions employed are suitably the same as those described in the specific example with reference to Fig. 1. The channel-forming fibres may also be of a similar type, of any desired diameter to correspond with that of the optical fibre to be introduced into the channel formed.
The channelled ceramic elements produced by the method of the invention have the advantages of good strength, rigidity and temperature stability, and are capable of acquiring a good surface finish, which can be maintained since wear and corrosion are negligible.
Furthermore, the alkaline earth metal titanates and zirconates, which are the preferred ceramic materials for use for forming the elements, are particularly advantageous for forming terminations and connector members for silica-based optical fibres, since the machining, lapping and polishing characteristics of these ceramics are similar to those of the optical fibres.
Claims (7)
1. A method of manufacturing a channelled ceramic element, which includes the steps of embedding one or more lengths of fibre composed of silica, with or without a coating of synthetic resin, in a body of powdered ceramic material which is of a nonsilica-based composition and can be sintered at a temperature not lower than 1 300 C, pressing the powder to form a self-supporting compact surrounding the fibre or fibres, and heating the assembly of the compact and fibre or fibres at a sufficiently high temperature and for a sufficient length of time to effect sintering of the compact and to cause the silica of the fibre or fibres to be absorbed by the surrounding ceramic material, so as to leave a channel or channels in the sintered ceramic material.
2. A method according to Claim 1, wherein the ceramic material employed consists of one or more alkaline earth metal titanates and/or zirconates, with or without minor proportions of additives.
3. A method according to Claim 1, or 2, for manufacturing a channelled ceramic element for forming an optical fibre termination or connector member, wherein the silica fibre of fibres employed for forming the channel or channels is or are of the same diameter as the optical fibre or fibres to be inserted into the channel or channels for termination or connection, and the sintering properties of the ceramic material are such that each channel formed has substantially the same diameter as the fibre employed for forming it.
4. A method according to Claim 1, 2 or 3, wherein the shape of the ceramic element is modified by machining after the sintering step.
5. An optical fibre termination or connector consisting of or including one or more channelled ceramic elements manufactured by a method according to Claim 1, 2, 3 or 4, each said element having one or more channels of straight or curved configuration formed therein.
6. A method according to Claim 1 for the manufacture of a channelled ceramic element, substantially as hereinbefore described by way of example with reference to any of the Figs.
1, 2, 3, 4 or 5 and 6, of the accompanying drawings.
7. An optical fibre termination or connector according to Claim 5, substantially as shown in, and as hereinbefore described with reference to, any of the Figs. 1, 2, 3, 4, or 5 and 6, of the accompanying drawings.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB8122209A GB2081468B (en) | 1980-08-06 | 1981-07-17 | Manufacture of channelled ceramic elements |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB8025661 | 1980-08-06 | ||
| GB8122209A GB2081468B (en) | 1980-08-06 | 1981-07-17 | Manufacture of channelled ceramic elements |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB2081468A true GB2081468A (en) | 1982-02-17 |
| GB2081468B GB2081468B (en) | 1984-02-01 |
Family
ID=26276470
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB8122209A Expired GB2081468B (en) | 1980-08-06 | 1981-07-17 | Manufacture of channelled ceramic elements |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2081468B (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO1987001464A1 (en) * | 1985-08-29 | 1987-03-12 | Amp Incorporated | Ferrule member for terminating fiber optic transmission member |
| EP0590586A1 (en) * | 1992-09-29 | 1994-04-06 | Tosoh Corporation | Optical fiber connector parts formed of zirconia |
| GB2317242A (en) * | 1996-09-13 | 1998-03-18 | Samsung Electronics Co Ltd | Optical fibre array module and fabrication method |
-
1981
- 1981-07-17 GB GB8122209A patent/GB2081468B/en not_active Expired
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO1987001464A1 (en) * | 1985-08-29 | 1987-03-12 | Amp Incorporated | Ferrule member for terminating fiber optic transmission member |
| EP0590586A1 (en) * | 1992-09-29 | 1994-04-06 | Tosoh Corporation | Optical fiber connector parts formed of zirconia |
| GB2317242A (en) * | 1996-09-13 | 1998-03-18 | Samsung Electronics Co Ltd | Optical fibre array module and fabrication method |
| GB2317242B (en) * | 1996-09-13 | 1998-11-04 | Samsung Electronics Co Ltd | Optical fibre array module and fabrication method |
Also Published As
| Publication number | Publication date |
|---|---|
| GB2081468B (en) | 1984-02-01 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PCNP | Patent ceased through non-payment of renewal fee |