Fiber optic splice protector and method for making same

Claim 2

A protected fiber optical splice, comprising: two pieces of optical fiber spliced together, with a moldable plastic encapsulating the splice and adjacent portions of said two optical fibers; a rigid tube surrounding said moldable plastic encapsulating said splice and at least a portion of said moldable plastic surrounding said adjacent portions of said two optical fibers; said moldable plastic filling all void space within said rigid tube and extending beyond said rigid tube along said fibers to form a strain relief supported by said tube.

Claim 3

A protected fiber optical splice as recited in claim 1 in which said plastic covering is of a cured epoxy or moldable plastic material.

Claim 4

A protected fiber optical splice as recited in claim 1 in which said plastic material further extends along said fibers from said tube and tapers to smaller diameters surrounding said fibers.

Claim 5

A protected fiber optical splice comprising: two pieces of optical fiber, each optical fiber having an optical core surrounded by jacketed cladding, each optical fiber having a respective end portion stripped of jacket and cladding to expose a short length of unclad optical core extending from cladded optical fiber, an end of each said optical core being co-axially aligned and fusion spliced together to form a continuous fiber optical guide; a rigid tube of metal having a bore and first and second ends, said continuous fiber optical guide being positioned in the bore of said rigid tube, said tube extending to cover said fusion splice with said ends being positioned to correspond in location with jacketed cladded portions of said optical fibers; a void free moldable plastic covering encapsulating the fusion splice, adjacent portions of said unclad optical core, and filling all space between said continuous fiber optical guide and the wall of said bore, said moldable plastic covering exiting each end of said rigid tube to form a strain relief for each optical fiber.

Claim 6

A protected fiber optical splice comprising: two pieces of optical fiber, each optical fiber having an optical core surrounded by jacketed cladding, each optical fiber having a respective end portion stripped of jacket and cladding to expose a short length of unclad optical core extending from cladded optical fiber, an end of each said optical core being co-axially aligned and fusion spliced together to form a continuous fiber optical guide; a rigid tube of metal having a bore and first and second ends, said continuous fiber optical guide being positioned in the bore of said rigid tube, said tube extending to cover said fusion splice with said ends being positioned to correspond in location with jacketed cladded portions of said optical fibers; a void free moldable plastic covering encapsulating the fusion splice, adjacent portions of said unclad optical core, and filling all space between said continuous fiber optical guide and the wall of said bore, said moldable plastic covering exiting each end of said rigid tube to form a strain relief for each optical fiber.

Claim 7

A protected fiber optical splice as recited in claim 2 in which said epoxy is urethane.

Claim 8

A protected fiber optical splice as recited in claim 4 in which said metal is aluminum.

Claim 9

A protected fiber optical splice as recited in claim 4 in which said metal is steel.

Claim 10

A protected fiber optical splice as recited in claim 4 in which said metal is Invar.

Claim 11

A protected fiber optical splice as recited in claim 5 in which said tube is of metal.

Claim 12

A protected fiber optical splice as recited in claim 9 in which said metal is aluminum.

Claim 13

A protected fiber optical splice as recited in claim 9 in which said metal is steel.

Claim 14

A protected fiber optical splice as recited in claim 9 in said metal is Invar.

Claim 17

A method as recited in claim 13 wherein said tube is of a metal.

Claim 18

A method as recited in claim 13 wherein said tube is of aluminum.

Claim 19

A method as recited in claim 13 wherein said tube is of steel.

Claim 20

A method as recited in claim 13 wherein said tube is of Invar.

Claim 21

A method as recited in claim 13 wherein said plastic material is a urethane material.

Claim 22

A method as recited in claim 13 and further comprising first and second molding fixtures surrounding said optical fibers and the first and second ends of said tube to direct uncured plastic into said tube and to form cured plastic coverings for said fibers extending from said tube along said fibers; and said plastic is cured within said fixtures and said tube.

Claim 23

A method as recited in claim 18 wherein said tube is of a metal.

Claim 24

A method as recited in claim 18 wherein said tube is of aluminum.

Claim 25

A method as recited in claim 18 wherein said tube is of steel.

Claim 26

The method as recited in claim 18 wherein said tube is of Invar.

Claim 27

A method as recited in claim 19 wherein said molding fixtures are split fixtures for removal from said cured plastic coverings.

Claim 28

A method as recited in claim 19 wherein the interior of said fixtures mold said coverings to taper from the outside diameter of said tube to a smaller diameter.

Claim 29

A method as recited in claim 19 wherein one said molding fixture has an opening for injecting uncured plastic material into said fixture and said tube, and the other said molding fixture has an opening for removing air displaced by said injected plastic material.