Optical fiber coupler packaging arrangement and a method of manufacture the same

Claim 2

A packaged optical fiber coupler comprising: a plurality of optical fibers each including jacketed portions separated by a respective unjacketed portion, the unjacketed portions of the fibers being formed of a fragile optical material and being fused together along a length thereof for coupling light from one fiber to another fiber; a generally trough-shaped support element having open end areas opposite each other, said support element being formed by comprising a pair of side walls interconnected along adjacent elongated edges and spaced apart along the edges opposite the interconnected edges to form an open top area therebetween, said support element being formed of a nickel-iron alloy having about 36% nickel and about 64% iron; a protective shield formed of a plastic material and extending around the outer surface of each of said side walls and across the open top area between said opposite edges, the interior portions of said trough-shaped support element and said protective shield thereby defining a protected inner area to protect the fused length of said fibers, and a housing in which said support element is mounted, the unjacketed portions of said fibers being adhesively secured within the trough formed by the side walls of said support element so that said fibers extend through said open end areas and beyond said support element to support and protect said fused length contained within said protected area from thermal shock, wherein said housing provides additional protection to said fused region.

Claim 3

A packaged optical fiber coupler in accordance with claim 1 further including a pair of tubular bend limiters, one of said bend limiters surrounding one of said jacketed portions and the other of said bend limiters surrounding the other end of said jacketed portions.

Claim 4

A packaged optical fiber coupler in accordance with claim 1 wherein said housing is formed by a pair of side wall members interconnected along adjacent elongated edges and spaced apart along the edges opposite the interconnected edges to form an open area, said support element being secured in said housing with the open area between said opposite edges of said support element being adjacent the interconnected edges of said housing.

Claim 5

A packaged optical fiber coupler in accordance with claim 3 wherein a body of encapsulant material fills the inside of said housing and surrounds said support element.

Claim 6

A packaged optical fiber coupler in accordance with claim 3 wherein said opposite edges of said housing have flanges extending therefrom.

Claim 7

A packaged optical fiber coupler in accordance with claim 3 wherein the opposite ends of said housing include tubular bend limiters through which the jacketed portions of said fibers extend.

Claim 8

A packaged optical fiber coupler comprising: a plurality of optical fibers each including jacketed portions separated by a respective unjacketed portion, the unjacketed portions of the fibers being formed of a fragile optical material having a first thermal coefficient of expansion and being fused together along a length thereof for coupling light from one fiber to another fiber; a generally trough-shaped support element having open end areas opposite each other, said support element comprising a pair of side walls interconnected along adjacent elongated edges and spaced apart along the edges opposite the interconnected edges to form an open area therebetween, said support element being formed of a metallic alloy having a second coefficient of thermal expansion, the difference between said first and second coefficients of thermal expansion being not greater than the difference between the thermal coefficient of expansion of glass and the thermal coefficient of expansion of a nickel-iron alloy having about 36% nickel and about 64% iron; a protective shield extending around the outer surface of each of said side walls and across the open top area between said opposite edges, the interior portions of said trough-shaped support element and said protective shield thereby defining a protected inner area to protect the fused length of said fibers; and a strip-shaped support member also formed of said metallic alloy and located entirely within said protected inner area; wherein the unjacketed portions of the optical fibers are adhesively secured to said strip-shaped support member at two spaced apart locations, one of which is adjacent one end of the fused length and the other of which is adjacent the other end of the fused length to support and protect said fused length from thermal shock, the unjacketed portions of said fibers being adhesively secured within the trough defined by said trough-shaped support element in the vicinity of either end thereof so that said fibers extend through said open end areas and beyond said support element to further support and protect said fused length and said strip-shaped support member contained within said protected area from thermal shock.

Claim 9

A packaged optical fiber coupler comprising: a plurality of optical fibers each including jacketed portions separated by a respective unjacketed portion, the unjacketed portions of the fibers being formed of a fragile optical material having a first thermal coefficient of expansion and being fused together along a length thereof for coupling light from one fiber to another fiber; a generally trough-shaped support element having open end areas opposite each other, said support element comprising a pair of side walls interconnected along adjacent elongated edges and spaced apart along the edges opposite the interconnected edges to form an open area therebetween, said support element being formed of a metallic alloy having a second coefficient of thermal expansion, the difference between said first and second coefficients of thermal expansion being not greater than the difference between the thermal coefficient of expansion of glass and the thermal coefficient of expansion of a nickel-iron alloy having about 36% nickel and about 64% iron; a protective shield extending around the outer surface of each of said side walls and across the open top area between said opposite edges, the interior portions of said trough-shaped support element and said protective shield thereby defining a protected inner area to protect the fused length of said fibers; and a strip-shaped support member also formed of said metallic alloy and located entirely within said protected inner area; wherein the unjacketed portions of the optical fibers are adhesively secured to said strip-shaped support member at two spaced apart locations, one of which is adjacent one end of the fused length and the other of which is adjacent the other end of the fused length to support and protect said fused length from thermal shock, the unjacketed portions of said fibers being adhesively secured within the trough defined by said trough-shaped support element in the vicinity of either end thereof so that said fibers extend through said open end areas and beyond said support element to further support and protect said fused length and said strip-shaped support member contained within said protected area from thermal shock.

Claim 10

A packaged optical fiber coupler in accordance with claim 7 wherein said protective shield is made of a shrinkable material that is shrunk in place to provide tight contact between said support element and said shield.