MXPA01007221A - Ganged boxes for holding optical components - Google Patents

Abstract

A box (48) for holding optical components (50) comprising a base (58) having an upper surface for receving a layer of optical components (50), the base (58) being attachable into a fiber-optic device (50). A clamping bar (66) attached to the base (58) over the layer of optical components (50), such that the layer of optical components (50) is held in place, with the optical fiber leads of the optical components (50) extending outside of opposite ends of the box for splicing.

Description

COUPLED BOXES TO SUPPORT OPTICAL COMPONENTS PRIORITY CLAIMINDICATION This application claims priority benefit under 35 U.S.C. § 120 of the provisional patent application E.U.A. series No. 60/116182 filed January 14, 1999, the content of which is based on and incorporated herein by reference in its entirety.

FIELD OF THE INVENTION The present invention relates generally to improvements to the field of optical components, and more particularly to aspects of systems and methods for holding optical components in position in a device.

TECHNICAL BACKGROUND A number of devices and systems are currently being manufactured and developed for use in fiber optic networks. These devices and systems include optical amplifiers to provide direct amplification of fiber optic signals without the need to convert the light signal into an electrical signal. Those fiber optic devices and systems typically include a number of optical components that have fiber terminals that must be cut together. Fiber optic terminals are easily damaged. Structures have been developed to mount the optical components in the fiber optic devices and to house the terminals cut out of danger. A disadvantage of the mounting structures of optical components that are currently used is that they require a relatively large amount of space within the fiber optic device. This is increasingly problematic as the trend in fiber optic devices is toward smaller packages. In this way there is a need for a system for mounting optical components within a fiber optic device that protects the optical components while efficiently utilizing the available space.

BRIEF DESCRIPTION OF THE INVENTION These and other disadvantages of the prior art are faced by the present invention. A first embodiment of the invention provides a box for holding optical components, which includes, a base having a surface for receiving multiple optical components, the base being addable in a fiber optic device. A clamping bar is adhered to the base on the optical components, so that the optical components are held in place by friction between the clamping bar and the base, with the optical fiber terminals of the optical components extending outward from opposite ends of the cutting box. A further embodiment of the invention provides a method for holding optical components in a fiber optic device. The method includes the steps of laying optical components on a base having a surface for receiving the optical components and adhering a clamping bar on the layer of optical components, so that the optical components are held in place by friction between the bar and the base, with the fiber optic terminals of the optical components extending beyond opposite ends of the cutting base. Additional features and advantages of the invention will be set forth in the detailed description that follows, and in part will be readily apparent to those skilled in the art from the description or will be recognized upon practicing the invention as described in the written description and claims thereof, as well as in the drawings appended thereto. It should be understood that the general description mentioned above and the following detailed description are merely illustrative of the invention, and are designed to provide an overview or working structure for understanding the nature and character of the invention as claimed. The appended drawings are included to provide further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiment (s) of the invention, and together with the description serve to explain the principles and operation of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS Figures 1 to 4 are perspective views of typical optical components that are used in fiber optic devices. Figure 5 is a perspective view of an optical component holder. Figure 6 is an exploded perspective view of the optical component holder of Figure 5, including optical components and adhesion devices. Figure 7 is an exploded perspective view of a second holder of optical components including an optical component and adhesion devices. Figure 8 is a perspective view of a bank of four optical component bays. Figure 9 is a top view of two optical component bays. Figure 10 is a top view of a first embodiment of a coupled component case according to the present invention. Figure 11 is a front view of a second embodiment of a coupled component case according to the present invention.

Figure 12 is a top view of a second embodiment of a component case coupled in accordance with the present invention. Fig. 13 is a front view of the second embodiment of a component case coupled in accordance with the present invention. Fig. 14 is a perspective view of a pad for retaining bottom shaping components in accordance with the present invention. Fig. 15 is a perspective view of a retaining pad of upper shaping components according to the present invention. Fig. 16 is a perspective view of an optical fiber device including a box for components coupled in accordance with the present invention. Figure 17 is a flow chart of a first embodiment of a method according to the present invention for holding optical components in a fiber optic device.

DETAILED DESCRIPTION OF THE INVENTION The present invention will be described more fully below with reference to the appended drawings, in which the presently preferred embodiments of the invention are shown. However, the described invention can be made in various forms and should not be considered as limited to the illustrative embodiments set forth herein. Rather, those representative embodiments are described in detail so that this description is thorough and complete, and completely transmits the structure, operation, functionality and potential scope of applicability of the invention to those skilled in the art. Figures 1 to 4 are perspective views of a number of optical components 10a-d that are currently used in the construction of fiber optic devices, such as optical amplifiers. These optical components typically include a body or packing 12a-d and fiber optic terminals 14a-d extending out of the body. Certain optical components, such as those shown in Figures 1 and 2, are manufactured with rectangular packages 12a-b. The typical dimensions of these packages are typically in the order of a few millimeters or tens of millimeters. For example, the illustrative packages illustrated in these figures may have dimensions of approximately 5.6 mm x 5.6 x 38 mm and 6.4 mm x 6.4 mm x 38 mm. As shown in Figures 1 and 2, the rectangular optical components have rectangular tabs 16a, 16b projecting outwardly from the component bodies. These tabs 16a, 16b have holes 17 for receiving plastic pressure rivets that are used to mount the component to a printed circuit board or other support structure.

Other optical components, such as those shown in Figures 3 and 4, have cylindrical packings 12c, 12d. The typical dimensions for cylindrical packages that are commonly used are in the order of a few millimeters in diameter by a few tens of millimeters in length. The illustrated example may have typical respective diameters of 3.5 mm and 5.5 mm and lengths of 30 mm and 53-54 mm. The body 12a-d of an optical component 10a-d is typically mounted on a printed circuit board or other support structure, and the fiber optic terminals are then cut to other fiber optic terminals 14a-d, as required. Figure 5 shows a perspective view of a component holder 18 which is used to mount a pair of cylindrical optical components 10c, 10d, in a device. The component holder 18 is typically made of a polymer filled with glass, or other suitable material. Illustrative of a polymer filled with glass is Ultem 2300 made by General Electric Corp., used because its coefficient of thermal expansion is close to that of the optical fiber, and it is moldable, 'machinable and rigid, and likewise has other useful properties. As shown in Figure 5, the component holder 18 includes a V-shaped top groove 20a and a V-shaped bottom groove 20b that are formed to receive cylindrical optical components 10c, 10d. The upper groove 20a is formed to receive a cylindrical optical component 10c with a diameter smaller than the lower groove 20b that is formed to receive a cylindrical optical component 10d with a larger diameter. The component holder 18 further includes a flat base 22 having a pair of holes 24 for receiving pressure rivets for mounting the component holder 18 to a printed circuit board or other support structure. In addition, the component holder 18 has a slot 26 for receiving a cable tie 28, or snap fastener (not shown). Figure 6 shows a perspective view of the component holder 18 shown in Figure 5, with optical components 10c, 10d placed in the V-shaped upper and lower grooves 20a, 20b. A cable tie 28 is secured around the component holder 18 and the optical components 10c, 10d. The plastic pressure rivets 30 are then used to mount the component holder 18 loaded on a printed circuit board 76 or other support structure. Figure 7 shows a perspective view of the structures that are used to mount the rectangular optical component 10a on a printed circuit board 76 or other support structure. The plastic pressure rivets 32 are used to mount the optical component 10a on a rectangular component holder 34. The tabs 36 on the base of the rectangular component holder 34 are provided to mount the component holder 34 to a motherboard (not it shows). These tongues 36 are provided with holes 37 for receiving plastic pressure rivets 38.

The use of fiber optic terminals is problematic. The cutting of fiber optic terminals is a precise task, sometimes requiring several attempts. The optical components, therefore, are typically provided with relatively long terminals. This allows cuts that are not well made to come off and the terminals to be cut again until a successful cut is achieved. Fiber optic terminals are also easily damaged; therefore, structures have been developed to protect the long fiber curls that may result after the cutting of fiber optic terminals. Figure 8 shows a perspective view of "bays" 40 of four optical components. Each of the bays 40 includes a pair of curved fiber guides 42, and at least one component holder 18 located between the fiber guides 42. The optical components 10 can be adhered to the component holders 18, as described above , by seating them in the upper and lower V-shaped reception grooves 20a, 20b and fixing them in place using cable ties. The optical component holders 18 and the fiber guides 42 are aligned in such a manner that the optical fiber terminals 48 emerging from the optical components 10 run tangentially to the fiber guides 42. The fiber guides 42 are used for guiding the fiber optic terminals 14 securely to central coil elements (not shown), wherein the fiber optic terminals 14 are cut to fiber terminals 14 of other components.

A benefit of the bay method for holding optical components is that it offers versatility. A variety of combinations of optical components can be held in a typical bay. The use of bays, while being advantageous in many aspects, also requires a relatively large amount of space. This relatively large amount of space is required to allow the containers, and access for tools for adhesion to a base and for adjusting the optical components, etc. The space requirements are illustrated in Figure 9, which shows a top view of two adjacent bays. The system illustrated requires that each pair of fiber guides 42 be separated from one another by a distance, illustrated by a double arrow 44. This distance is typically in the order of 80.86 mm. In addition, the adjacent bays must be separated from one another by a distance, illustrated by a double arrow 46, which is typically 11.43 mm. In this way, each bay of the type illustrated in Figure 9 requires approximately 924 mm2 of "floor space" on the printed circuit board or other support structure. This amount of floor space accommodates one to four optical components 10, depending on the height of the module. For example, a module that is currently used has a height of approximately 12 mm with stacking of two-story components. Another module that is currently used has a height of 25 mm, which can handle stacking of four-story components.

Thus, in a module with a height of 19 mm, to hold 10 optical components would require four bays and would use approximately 3,697 mm2 of floor space on a printed circuit board or other support structure. In some newer modules, this area would consume approximately one third of the total available space. Due to the increasing complexity of optical devices and spatial limitations, there is a need to load more and more optical components into an optical device of a given volume. In order to use the available space more efficiently, a "coupling" arrangement has been developed. Figures 10 and 11 show, respectively, top and front views of a first embodiment of a coupled component case 48 according to the present invention. The illustrated case for components 48 supports two layers of cylindrical optical components 10, a lower layer 50 of 7 optical components 10 with a diameter of 5.5. mm, and an upper layer 52 of 6 optical components with a diameter of 3.5 mm. It will be appreciated that it would be possible to vary the number, size and shape of the components 10, as well as the number of layers, without departing from the spirit of the present invention. In the present embodiment, the box 48 comprises a base 54 that is secured to a printed circuit board 76 or other support structure using screws 56, although other securing techniques may be used, as desired. The base includes a number of slots 58, which have a depth and width that are selected so that when the cylindrical components 10 are loaded into the slots 58, the slots 58 hold the components 10 in place, close to, and substantially parallel with, one with another. Once the lower layer 50 of components 10 is placed in the slots 58, a spacer 60 is placed over the top of the bottom layer 50 of components 10, in preparation for the placement of the top layer 58 of components 10. In one embodiment of the invention having only a single layer of optical components 10, this spacer 60, of course, would not be necessary. The spacer 60 includes a number of cradles 62 on its upper and lower surfaces which are shaped to conform closely to the profiles of the cylindrical optical components 10 that are held in place. The spacer 60 can be machined metal or, alternatively, it can be made of a conformable material, such as foam or silicone. After the lower layer of components 50 has been laid in the grooves 58 in the base of the component case 48, the spacer 60 is then placed on top of the lower layer of components 50 so that the cradles 62 adjust on the lower layer of components 50. The upper layer of components 52 then lies in the cradles 62 on the upper surface of the spacer 60.

After the components have been placed, a clamping bar 64 is placed over the top layer of the optical components 52 and adhered to the base 54 by screws 66 at either end. In an alternate embodiment, one side of the clamping bar 64 can be adhered to the base 54 using a hinge arrangement. As shown in Figures 10 and 11, the clamping bar 64 is relatively narrow in width, covering only one end of the two layers of optical components 50, 52. It has been determined that this relatively narrow clamping bar 64 provides support acceptably safe, while allowing most of each of the optical components to remain exposed. This exposure can be useful; for example, it allows printed information on the side of each component to remain visible. In the present embodiment, the spacer element 60 has a width so that it fits completely under the clamping bar 64. In the present embodiment, the clamping bar 64 includes a thin foam layer 68 adhered to its lower side to provide damping for the upper layer of optical components 52. The optical fiber terminals of the upper and lower layers 50, 52 of optical components extend outwardly from either end of the box for cutting components 48. A possible cutting arrangement that can be used with the box for components shown in the figures and 11 is shown in figure 18 and is discussed immediately. The box for components shown in figures 10 and 11 occupies an area of 2377.79 mm2 for 13 components. This provides an area saving of approximately 1319 mm2 when compared to the bay arrangement described above. Figures 12 and 13 show, respectively, top and front views of a second embodiment of a coupled component case 48 according to the present invention. In this embodiment, the base 72 and the cover 74 are machined, respectively, from aluminum and stainless steel. The base 72 has a U-shaped profile, with a flat bottom surface resting against the printed circuit board 76. The use of the box for components 48 shown in Figs. 12 and 13 is similar to the box that is shown in Figures 10 and 11. A first component layer 78 is laid on the bottom 72 of the box 72. If desired, a "sticky" polyurethane layer can be fixed to the bottom of the box 72 before it is Store the first layer of optical components in position. This polyurethane layer can be useful for preventing undesirable movement of the components before the upper layers of components and the foam strips have been held in place by a clamping bar 74. The forming material 80, of which are illustrative The foams and elastomers are then used to separate the layers of optical components from one another. The forming material 80 can take a number of forms, as desired. In one embodiment, foam strips are used. These strips are molded to include N # of cribs formed to receive optical components 10, similar to the cribs shown in the spacer element 60 shown in Figure 11.

When all the layers of optical components and foam strips have been laid in place, the clamping bar 74 is adhered using screws 84, or other insurers. The foam has a number of desirable characteristics. It allows the material surrounding the optical components 10 to be compressed sufficiently for fastening purposes. As an added benefit, the proper foam material provides a certain amount of flexure to help support the components. The main benefit of the foam is that it allows the addition and subtraction of components with only an adjustment in the amount of foam. The area required by the box for components shown in figures 12 and 13 is 1869 mm2, providing a space saving of 1828 mm2 over the bay arrangement described above. Figs. 14 and 15 show perspective views of shaping component holding pads 86, 88 which, in a further embodiment of the present invention, are used to separate layers of optical components within a housing for components 48. In an embodiment Currently, the retaining pads of shaping components 86, 88 are made of silicone or any other suitable conformable material with a high compression fixation point. The first pad 86, includes a flat bottom surface 90, which rests on the floor of the component case 48. The top surface 92 of the retention pad includes a number of integrally formed cradles 94, 96, which are formed to receive optical components 10. Two of the cradles 94 are formed to receive cylindrical components of the smallest diameter (3.5 mm), such as that shown in figure 3, and the other three cradles 96 are formed to receive more diameter cylindrical components large (5.5 mm) 10d. The second pad #, has # cradles on its lower surface 98 and its upper surface 100. The cradles on the lower surface 98 of the second pad 88 correspond in position to the cradles on the upper surface 92 of the first pad 86. , the first retention pad 86 is placed on the base of a component case 48. The optical components 10 are then laid on the receiving cradles, and the second retention pad 88 is laid on top on the first layer 50. of components. A second component layer 52 is laid on top of the second retention pad 88. The cover plate, or clamping bar 64, is then placed on top of the second component layer 52 and screwed into its place. In this embodiment, a layer of silicone or other conformable material is fixed to the underside of the clamping bar to protect the optical components to ensure that the optical components are held securely in place. It would also be within the spirit of the present invention to provide a third shaping component retention pad (not shown) to cover the upper layer 52 of the component prior to adhesion of the clamping bar 64. Figure 14 shows a view in FIG. perspective of an optical amplifier module 102 including a coupled component case 48 according to the present invention. The optical components are all stored together in the box 48, with their fiber optic terminals 14 extending out of either end. The terminals are then measured, cut out and cut together, and the resultant optical fiber loops are then stacked by wrapping them around a portion of "track lane" 108 inside the device. Figure 15 shows a method 110 according to the present invention for holding optical components in a fiber optic device. In this method, the optical components are charged to a coupled component in a series of production steps. In step 112, a base such as that mounted to a fiber optic device. In step 114, a first shaping component holding pad is loaded on a base. In step 116, any optical components that are to be loaded onto the upper surface of the first component retention pad in this first stage of manufacture are laid in position. In step 118, a second shaping component holding pad is placed on top of the first shaping component holding pad. In step 120, any optical components that are to be loaded onto the upper surface of the second component retention pad in this first manufacturing step are laid in position. In step 122, a clamping bar, adheres to the base on the retaining pads of shaping components and the optical components to hold them in place. In step 124, the optical terminals of the optical components are cut together. In step 126, any resulting loops of fibers are stacked in a track lane within the optical device. In step 128, subsequent production steps, in which additional optical components are added to the component case, are achieved by repeating steps 116 through 126 in as many stages of production as desired until the optical components have been Fully charged in the component box. It will be appreciated that the above method can be easily modified, as desired, to accommodate other bases, spacers, fiber optic devices, etc. It should be noted that the number of layers of optical components, as well as the number of retaining pads of conformal components or spacers can also be modified. In addition, of course, if desired, all optical components can be loaded into the component case in one step. It will be apparent to those skilled in the art that various modifications and variations may be made in the present invention without departing from the spirit and scope of the present invention. In this way, it is intended that the present invention cover the modifications and variations of this invention, provided they are within the spirit of the claims and their equivalents that are attached.

Claims (17)

NOVELTY OF THE INVENTION CLAIMS

1. - A box for holding optical components, comprising: a base having an upper surface for receiving a plurality of optical components, the base is addable in a fiber optic device; a clamping bar which is addable to the base on the plurality of optical components, so that when the clamping bar adheres to the base, the plurality of optical components is held in place by friction, with the fiber optic terminals of the plurality of optical components extending outwardly from opposite sides of the box.

2. The box according to claim 1, further characterized in that the upper surface of the base includes a plurality of grooves formed to receive the plurality of optical components.

3. The box according to claim 2, further characterized in that the plurality of grooves support a first layer of optical components, and further includes: a spacer having a lower surface formed to fit over the plurality of optical components and a surface top formed to receive a second plurality of optical components, so that when the gripper bar adheres to the base, the plurality of optical components, said spacer, and the second plurality of optical components are held in place by friction.

4. The box according to claim 3, further characterized in that the spacer is made of metal.

5. The box according to claim 3, further characterized in that the spacer is made of flexible formable material.

6. The box according to claim 1, further characterized in that the clamping bar includes a layer of flexible formable material for contacting the second plurality of optical components.

7. The box according to claim 1, further comprising a layer of adhesive for receiving optical components adhered to the upper surface of the base.

8. The box according to claim 1, further characterized in that the base has a generally U-shaped profile, having a bottom surface that is addable to an optical fiber device and a pair of side walls that is they extend upwards that enclose the plurality of optical components.

9. The box according to claim 1, further including: a first shaping component holding pad containing the upper surface of the base, the upper surface of the first shaping component holding pad being formed for receiving a first plurality of optical components; a second shaping component holding pad having a bottom surface formed to fit over the first plurality of optical components, the second shaping component holding pad has an upper surface formed to receive a second plurality of optical components, so that when the clamping bar adheres to the base on the second plurality of optical components, the first retention pad of shaping components, the first plurality of optical components, the second retention pad of shaping components, and the second plurality of optical components are held in place by friction.

10. The box according to claim 9, further characterized in that the clamping bar includes a layer of flexible formable material so that when the clamping bar adheres to the base, the layer of flexible formable material contacts the second plurality of optical components.

11. The box according to claim 1, further characterized in that after the base has been adhered to the fiber optic device and the holding bar has been adhered to the base on the plurality of optical components, the terminals of Fiber optics of the optical components extend outward from the opposite sides of the box to a track rail in the fiber optic device.

12. - The box according to claim 11, further characterized in that the fiber terminals are cut together, resulting in optical fiber loops that wrap around the track lane.

13. A method for holding optical components in a fiber optic device, comprising the steps of: (a) placing a plurality of optical components on a base having an upper surface configured to receive said plurality of optical components; (b) adhering a clamping bar to said base on the plurality of optical components, such that said plurality of optical components is held in place by the clamping action of the clamping bar and the base.

14. A method for holding optical components in a fiber optic device, comprising the following steps: (a) placing a first plurality of optical components on a base having an upper surface for receiving the optical components; (b) placing on the top of said first plurality of optical components a spacer having a bottom surface formed to fit over the plurality of optical components and an upper surface formed to receive a second plurality of optical components; (c) placing said second plurality of optical components on the upper surface of the spacer; (d) adhering a clamping bar to the base, such that said first plurality of optical components, said spacer, and the second plurality of optical components are held in place by the clamping action.

15. A method for holding optical components in a fiber optic device, comprising the steps of: (a) placing a first retention pad of shaping components on the upper surface of a base, said first component retention pad of shaping has an upper surface for receiving a first plurality of optical components; (b) placing said first plurality of optical components on the upper surface of the first shaping component holding pad; (c) placing a second retention pad of shaping components on top of the first plurality of optical components, the second retention pad of shaping components has a bottom surface formed to fit over the first plurality of optical components, and an upper surface configured to receive a second plurality of optical components; (d) placing a second plurality of optical components on the upper surface of the second shaping component holding pad; (e) adhering a tie rod to the base so that the first forming component holding pad, the first plurality of components, the second component holding pad, and the second plurality of components are held in place by clamping forces, with fiber terminals of optical components extending outward from opposite ends of the cutting box.

16. The method according to claim 15, which includes the additional steps (f) and (g) made after step (e): (f) cutting optical terminals extending from the optical components; (g) Stacking the resulting curls of optical fiber.

17. A method for holding optical components in a fiber optic device, comprising the steps of: (a) placing a retention pad of shaping components that fits over a top surface of a base, the component retention pad of shaping has an upper surface for receiving a plurality of optical components; (b) placing at least one optical component on the upper surface of the shaping component holding pad, in which at least one optical component has fiber optic terminals extending beyond the base; (c) adhering a clamping bar to the base so that the retention pad of forming components and the at least one optical component placed on the retention pad of forming components are held in place; (d) cutting the fiber optic terminals; (e) remove the clamping bar; (f) repeat steps (b) through (e) to install additional optical components.