A method for manufacturing a hollow-core anti-resonant optical fiber jumper

Abstract

A method for making a hollow-core anti-resonant optical fiber jumper, the specific steps of which include: using a precision cutting device to cut the two ends of a 30cm long HC‑ARF into an angle less than 1°, ensuring that the cut end face is intact and free of cracks; fusing the cut HC‑ARF with a 10cm long coreless optical fiber to prevent the cladding tube from collapsing; using two-component epoxy resin glue to accurately inject into the ceramic ferrule to ensure that the glue is evenly filled and provide mechanical support; passing the fused optical fiber assembly into a protective sleeve and inserting it into the ceramic ferrule, and performing end face grinding after curing to ensure that there is no chipping, cracking, or scratches. The final product undergoes strict testing and is covered with a dust cap to form a compact and beautiful hollow-core anti-resonant optical fiber jumper. The present invention improves the stability and reliability of the connector and reduces signal transmission loss by optimizing the cutting, fusing, glue injection, and grinding processes. It is suitable for a variety of optical fiber interfaces and has broad application prospects.

Description

Technical Field

[0001] The invention relates to the technical field of optical fiber production, in particular to a method for manufacturing a hollow-core anti-resonance optical fiber jumper. Background Art

[0002] Hollow-core anti-resonant fiber (HC-ARF) utilizes a unique transverse cladding structure, allowing light to propagate within a longitudinal air core. This fiber exhibits advantages such as low confinement loss, low nonlinearity, low dispersion, low latency, and a high damage threshold. These properties make it an ideal choice for high-power laser energy transmission, fiber probes, and high-speed optical communications. It is widely used in sensing, nonlinear optics, high-power ultrafast lasers, and ultraviolet / infrared light transmission.

[0003] Despite its numerous advantages, HC-ARF still faces some drawbacks in practical applications. Existing HC-ARF connection technologies are complex and time-consuming, making them difficult to meet the demands of rapid integration and mass production. Traditional connection methods often require precise alignment and complex processes, resulting in high manufacturing costs and low efficiency. Furthermore, the stability and reliability of existing connectors need to be improved, especially under high power conditions and harsh environments, where signal attenuation and connection failure are common. Summary of the Invention

[0004] To address these shortcomings, the present invention provides a highly efficient and stable hollow-core antiresonant fiber connector and its manufacturing method. This approach simplifies the integration process, improves production efficiency, and reduces manufacturing costs, while ensuring that the performance of the connected fiber remains unaffected. The connector should be easy to maintain, convenient to install and remove, and highly compatible with various types of HC-ARF and other standard fiber interfaces, thereby promoting the widespread adoption and development of this advanced technology.

[0005] In order to solve the above technical problems, the present invention adopts the following technical solutions:

[0006] A method for manufacturing a hollow-core anti-resonant optical fiber jumper, the method comprising the following steps:

[0007] S1. Use a precision cutting device to cut both ends of a 30 cm long hollow-core antiresonant optical fiber. The cutting angle is less than 1°, and the cut end face is intact and free of cracks.

[0008] S2. Splice the two ends of the cut hollow-core anti-resonance fiber to a 10 cm long coreless fiber in a fusion splicer to ensure that the cladding tube in the hollow-core anti-resonance fiber does not collapse after the splicing.

[0009] S3. Prepare two-component epoxy resin glue and inject it into the fiber optic connector's ceramic ferrule through the inlet using a syringe. Ensure that the glue is evenly mixed, pure, and free of bubbles. When injecting the glue, ensure that the glue completely fills the gaps inside the ceramic ferrule to secure the fiber and provide mechanical support.

[0010] S4, inserting the hollow-core anti-resonance fiber and the coreless fiber assembly after the fusion splicing into a protective sleeve; then directly inserting the hollow-core anti-resonance fiber with the protective sleeve and the coreless fiber into the ceramic ferrule to obtain a composite optical fiber;

[0011] S5, placing the composite optical fiber in a curing furnace for heating and curing, and taking it out and cooling it to room temperature after curing is completed;

[0012] S6. Use a fiber cutting tool to cut off the coreless optical fiber extending from the end face of the composite optical fiber ceramic ferrule, and assemble the connector parts;

[0013] S7. Install the connector on the grinding disc and use sandpaper of different mesh sizes to grind in the order of coarse grinding, medium grinding, fine grinding and polishing. Each step needs to be evenly sprayed with pure water and cleaned;

[0014] S8. Check the end face after grinding to ensure there is no chipping, cracking, or scratches. Put on dust caps for qualified products and obtain the final hollow-core anti-resonance fiber jumper.

[0015] In a preferred solution, in step S1 and step S2, the core diameter of the hollow-core antiresonant fiber is 45±2um, and the outer diameter of the hollow-core antiresonant fiber is 270±20um; the cladding diameter of the coreless fiber is 300±2um, and the coating diameter is 450±1um.

[0016] In the preferred solution, in step S1, the bare fiber length reserved after the hollow-core antiresonant fiber is cut is within 0.5 cm; in step S6, the bare fiber length reserved for the coreless fiber is 0.5 cm; in step S7, after the composite fiber is polished, the length of the remaining coreless fiber is ensured to be within 1.5 mm.

[0017] In a preferred solution, in step S5, the temperature of the heating and curing is 80° C.-85° C., and the time is controlled to be 30 min-40 min.

[0018] In the preferred solution, the specific operation steps of step S4 are as follows:

[0019] S4.1. Place the spliced ​​hollow-core antiresonant fiber and coreless fiber assembly into a white protective sheath with an appropriate inner diameter to protect the fiber from external environmental influences and ensure that the fiber remains stable during subsequent processing.

[0020] S4.2. After inserting the protective sheath, check that the optical fiber is correctly centered and not twisted or bent, ensuring that the straightness of the optical fiber is not affected;

[0021] S4.3. Insert the hollow-core antiresonant fiber with a protective sleeve and the coreless fiber assembly into the ceramic ferrule, ensuring that the fiber protrudes from the ceramic ferrule for a length of ≥1 cm to prevent fiber retraction during subsequent thermal curing. During the insertion process, ensure that the fiber enters the ceramic ferrule smoothly to avoid excessive pressure or damage to the fiber, and ensure that the gap between the fiber and the ceramic ferrule is completely filled with the glue previously injected.

[0022] S4.4. After inserting the ceramic ferrule, further check the position of the optical fiber to ensure that the optical fiber is correctly positioned in the ceramic ferrule and the end face of the optical fiber is flush with the end face of the ceramic ferrule.

[0023] In the preferred solution, the specific operation steps of step S7 are as follows:

[0024] S7.1. Install the connector on the grinding wheel. After assembly, check that the ferrule passes through the ferrule fixing hole of the grinding wheel and can move elastically to ensure that the ferrule will not shift due to vibration during the grinding process.

[0025] S7.2. Select appropriate abrasive paper and stick it on the corresponding abrasive pad. Make sure the abrasive paper is stuck in the correct direction and is smooth and free of bubbles after abrasion to ensure a uniform abrasive surface.

[0026] S7.3. Place the grinding pad with sandpaper on the grinding machine and adjust the grinding speed and grinding time according to the parameters;

[0027] S7.4. During the grinding process, evenly spray pure water on the grinding paper to keep the grinding surface moist, reduce frictional heat, and prevent overheating and damage to the fiber end face;

[0028] S7.5. After each stage of grinding, thoroughly clean the ferrule end face, grinding disc, and sandpaper with pure water to remove any residual grinding particles and avoid cross contamination.

[0029] S7.6. Carry out the grinding in the order of coarse grinding, medium grinding, fine grinding and polishing, gradually improving the grinding accuracy to ensure that the final end surface is smooth and free of obvious scratches;

[0030] S7.7. During the grinding process, regularly check the end surface quality, use a microscope to magnify and observe the end surface condition, and adjust the grinding parameters in time to ensure that the grinding process is under control;

[0031] S7.8. After final grinding, use a high-power microscope to inspect the end surface quality to ensure there are no chipping, cracking, or scratches.

[0032] S7.9. Clean the end face after grinding. Use a dust-free paper dipped in an appropriate amount of alcohol to gently wipe it to remove any remaining moisture and impurities, ensuring that the end face is clean and tidy.

[0033] In a preferred embodiment, the optical fiber polishing parameters in step S7.3 are as follows:

[0034] Coarse grinding: Use 600-mesh abrasive paper, grind for 6 minutes, and grind at 75 rpm;

[0035] Medium grinding: Use 4000 mesh grinding paper, grinding time is 3 minutes, grinding speed is 75 rpm;

[0036] Fine grinding: Use 8000 mesh abrasive paper, grinding time is 6 minutes, grinding speed is 75 rpm;

[0037] Polishing: Use 12000 mesh abrasive paper, the grinding time is 10 minutes, and the grinding speed is 75 rpm.

[0038] A method for manufacturing a hollow-core anti-resonant optical fiber jumper, the method having the following advantages:

[0039] 1. The present invention uses a precision cutting device to cut both ends of the hollow-core anti-resonant optical fiber. The cutting angle is less than 1°, and the cut end face is intact and free of cracks, ensuring the flatness and optical performance of the fiber end face. During the fusion process, special attention is paid to preventing the cladding tube in the hollow-core anti-resonant optical fiber from collapsing, ensuring the integrity of the optical fiber's internal structure, thereby reducing losses during signal transmission.

[0040] 2. Use two-component epoxy resin glue and precisely inject it into the ceramic ferrule through a syringe to ensure that the glue is evenly mixed, pure, and free of bubbles. When injecting glue, the gaps inside the ceramic ferrule are completely filled. This not only fixes the optical fiber, but also provides the necessary mechanical support, enhancing the stability and reliability of the connector and reducing the risk of connection failure due to external vibration or impact.

[0041] 3. This invention rigorously controls the core diameter, outer diameter, and coating diameter of both the hollow-core antiresonant fiber and the coreless fiber, ensuring dimensional consistency. In particular, during the cutting and splicing processes, the remaining bare fiber length is precisely controlled to within 0.5 cm, ensuring smooth subsequent assembly. After final polishing, the remaining length of the coreless fiber is controlled to within 1.5 mm, further ensuring the compactness and aesthetics of the connector. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] The present invention will be further described below with reference to the accompanying drawings and examples:

[0043] Figure 1 This is a flowchart of the patent operation steps of the present invention;

[0044] Figure 2 This is a schematic diagram of the structure of the patented composite optical fiber of this invention.

[0045] In the figure: hollow-core antiresonant fiber 1, coreless fiber 2, protective sleeve 3, ceramic ferrule 4. DETAILED DESCRIPTION

[0046] Example 1: Method for manufacturing hollow-core anti-resonant optical fiber jumper

[0047] This embodiment describes in detail a method for manufacturing a hollow core anti-resonant fiber (HC-ARF) patch cord. The specific steps are as follows:

[0048] S1. Precision cutting:

[0049] A 30cm long hollow-core antiresonant fiber was cut using a high-precision automatic cutting device. The cutting angle was strictly controlled to less than 1° to ensure that the cut end face was intact and free of cracks. After cutting, the fiber end face was inspected to ensure it was flat and smooth to ensure the quality of subsequent fusion splicing.

[0050] S2. Welding:

[0051] The two ends of the cleaved hollow-core anti-resonance fiber were fused to a 10cm long coreless fiber in a fusion splicer. During the fusion process, special attention was paid to prevent the cladding tube in the hollow-core anti-resonance fiber from collapsing. By adjusting the fusion parameters and process, the fiber connection was ensured to be secure and free of any damage. After the fusion was completed, the quality of the fusion point was rechecked to ensure that it met the requirements.

[0052] S3, glue injection:

[0053] Prepare two-component epoxy glue and slowly inject it into the fiber optic connector's ceramic ferrule using a syringe. Ensure the glue is evenly mixed, pure, and free of bubbles. Ensure the glue completely fills the gaps within the ceramic ferrule to secure the fiber and provide mechanical support. After injection, allow the glue to cure and prevent shifting during subsequent operations.

[0054] S4. Protection and assembly:

[0055] S4.1 Place the spliced ​​hollow-core antiresonant fiber and coreless fiber assembly into a white protective sleeve with an appropriate inner diameter to protect the fiber from external environmental influences and ensure that the fiber remains stable during subsequent processing.

[0056] S4.2 After inserting the protective sleeve, carefully check whether the optical fiber is correctly centered and not twisted or bent to ensure that the straightness of the optical fiber is not affected;

[0057] S4.3 Insert the hollow-core antiresonant fiber with protective sleeve and the coreless fiber assembly into the ceramic ferrule, ensuring that the fiber protrudes from the ceramic ferrule for a length of ≥1 cm to prevent fiber retraction during subsequent thermal curing. During the insertion process, ensure that the fiber enters the ceramic ferrule smoothly to avoid excessive pressure or damage to the fiber, and ensure that the gap between the fiber and the ceramic ferrule is completely filled with the glue previously injected.

[0058] S4.4 After inserting the ceramic ferrule, further check the position of the optical fiber to ensure that the optical fiber is correctly positioned in the ceramic ferrule and the end face of the optical fiber is flush with the end face of the ceramic ferrule;

[0059] S5. Curing:

[0060] Place the composite optical fiber in a curing oven set at a preset temperature of 80-85°C for heating and curing, with the curing time controlled within 30-40 minutes. During the curing process, regularly check the temperature and time settings of the curing oven to ensure that the curing process proceeds smoothly. After curing is complete, remove the composite optical fiber and allow it to cool naturally to room temperature.

[0061] S6, cutting and assembly:

[0062] Use a dedicated fiber optic cutting tool to cut off the coreless fiber protruding from the end face of the composite fiber optic ceramic ferrule, ensuring that the end face is flat after cutting. Then, assemble the connector parts according to the standard process, ensuring that all parts fit tightly and the connection is firm;

[0063] S7, grinding:

[0064] S7.1 Install the connector on the grinding wheel. After assembly, check that the ferrule passes through the ferrule fixing hole of the grinding wheel and can move elastically to ensure that the ferrule does not shift due to vibration during the grinding process.

[0065] S7.2 Select appropriate abrasive paper and stick it on the corresponding abrasive pad. Make sure the abrasive paper is stuck in the correct direction and is smooth and free of bubbles after abrasion to ensure a uniform abrasive surface.

[0066] S7.3 Place the abrasive pad with sandpaper on the grinder and adjust the speed and grinding time according to the following parameters:

[0067] Coarse grinding: Use 600-mesh abrasive paper, grind for 6 minutes, and grind at 75 rpm;

[0068] Medium grinding: Use 4000 mesh grinding paper, grinding time is 3 minutes, grinding speed is 75 rpm;

[0069] Fine grinding: Use 8000 mesh abrasive paper, grinding time is 6 minutes, grinding speed is 75 rpm;

[0070] Polishing: Use 12000 mesh abrasive paper, grinding time is 10 minutes, grinding speed is 75 rpm;

[0071] S7.4 During the polishing process, evenly spray pure water on the polishing paper to keep the polishing surface moist, reduce frictional heat, and prevent overheating and damage to the fiber end face;

[0072] S7.5 After each stage of grinding, thoroughly clean the ferrule end face, grinding disc, and sandpaper with pure water to remove residual grinding particles and avoid cross contamination;

[0073] S7.6 Carry out the grinding in the order of coarse grinding, medium grinding, fine grinding and polishing, gradually improving the grinding accuracy to ensure that the final end surface is smooth and free of obvious scratches;

[0074] S7.7 During the grinding process, regularly use a microscope to magnify and observe the end surface condition, and adjust the grinding parameters in a timely manner to ensure that the grinding process is under control;

[0075] S7.8 After final grinding, use a high-power microscope to inspect the end surface quality to ensure there are no chipping, cracking, or scratches.

[0076] S7.9 Clean the polished end face by gently wiping it with a dust-free paper dipped in an appropriate amount of alcohol to remove any remaining moisture and impurities, ensuring that the end face is clean and tidy.

[0077] S8, testing and packaging:

[0078] Professional equipment is used to inspect the polished end faces to ensure they are free of chipping, cracking, and scratches. Qualified products are fitted with dust caps, resulting in the final hollow-core anti-resonant fiber patch cables. Unqualified products are re-polished or discarded to ensure they meet quality standards.

Claims

1. A method for manufacturing a hollow core anti-resonant optical fiber jumper, characterized in that: The preparation method comprises the following steps: S1. Use a precision cutting device to cut both ends of a 30 cm long hollow-core antiresonant optical fiber. The cutting angle is less than 1°, and the cut end face is intact and free of cracks. S2. Splice the two ends of the cut hollow-core anti-resonance fiber to a 10 cm long coreless fiber in a fusion splicer to ensure that the cladding tube in the hollow-core anti-resonance fiber does not collapse after the splicing. S3. Prepare two-component epoxy resin glue and inject it into the fiber optic connector's ceramic ferrule through the inlet using a syringe. Ensure that the glue is evenly mixed, pure, and free of bubbles. When injecting the glue, ensure that the glue completely fills the gaps inside the ceramic ferrule to secure the fiber and provide mechanical support. S4, inserting the hollow-core anti-resonance fiber and the coreless fiber assembly after the fusion splicing into a protective sleeve; then directly inserting the hollow-core anti-resonance fiber with the protective sleeve and the coreless fiber into the ceramic ferrule to obtain a composite optical fiber; S5, placing the composite optical fiber in a curing furnace for heating and curing, and taking it out and cooling it to room temperature after curing is completed; S6. Use a fiber cutting tool to cut off the coreless optical fiber extending from the end face of the composite optical fiber ceramic ferrule, and assemble the connector parts; S7. Install the connector on the grinding disc and use sandpaper of different mesh sizes to grind in the order of coarse grinding, medium grinding, fine grinding and polishing. Each step needs to be evenly sprayed with pure water and cleaned; S8. Check the end face after grinding to ensure there is no chipping, cracking, or scratches. Put on dust caps for qualified products and obtain the final hollow-core anti-resonance fiber jumper.

2. The method for manufacturing a hollow-core anti-resonant optical fiber jumper according to claim 1, wherein: In step S1 and step S2, the core diameter of the hollow-core antiresonant fiber is 45±2um, and the outer diameter of the hollow-core antiresonant fiber is 270±20um; the cladding diameter of the coreless fiber is 300±2um, and the coating diameter is 450±1um.

3. The method for manufacturing a hollow-core anti-resonant optical fiber jumper according to claim 1, wherein: In step S1, the bare fiber length reserved after the hollow-core antiresonant fiber is cut is within 0.5 cm; in step S6, the bare fiber length reserved for the coreless fiber is 0.5 cm; in step S7, after the composite fiber is polished, the length of the remaining coreless fiber is ensured to be within 1.5 mm.

4. The method for manufacturing a hollow-core anti-resonant optical fiber jumper according to claim 1, wherein: In step S5, the temperature of the heating and curing is 80° C.-85° C., and the time is controlled to be 30 min-40 min.

5. The method for manufacturing a hollow-core anti-resonant optical fiber jumper according to claim 1, wherein: The specific operation steps of step S4 are as follows: S4.

1. Place the spliced ​​hollow-core antiresonant fiber and coreless fiber assembly into a white protective sheath with an appropriate inner diameter to protect the fiber from external environmental influences and ensure that the fiber remains stable during subsequent processing. S4.

2. After inserting the protective sheath, check that the optical fiber is correctly centered and not twisted or bent, ensuring that the straightness of the optical fiber is not affected; S4.

3. Insert the hollow-core antiresonant fiber with a protective sleeve and the coreless fiber assembly into the ceramic ferrule, ensuring that the fiber protrudes from the ceramic ferrule for a length of ≥1 cm to prevent fiber retraction during subsequent thermal curing. During the insertion process, ensure that the fiber enters the ceramic ferrule smoothly to avoid excessive pressure or damage to the fiber, and ensure that the gap between the fiber and the ceramic ferrule is completely filled with the glue previously injected. S4.

4. After inserting the ceramic ferrule, further check the position of the optical fiber to ensure that the optical fiber is correctly positioned in the ceramic ferrule and the end face of the optical fiber is flush with the end face of the ceramic ferrule.

6. The method for manufacturing a hollow-core anti-resonant optical fiber jumper according to claim 1, wherein: The specific operation steps of step S7 are as follows: S7.

1. Install the connector on the grinding wheel. After assembly, check that the ferrule passes through the ferrule fixing hole of the grinding wheel and can move elastically to ensure that the ferrule will not shift due to vibration during the grinding process. S7.

2. Select appropriate abrasive paper and stick it on the corresponding abrasive pad. Make sure the abrasive paper is stuck in the correct direction and is smooth and free of bubbles after sticking. Ensure that the abrasive surface is uniform. S7.

3. Place the grinding pad with sandpaper on the grinding machine and adjust the grinding speed and grinding time according to the parameters; S7.

4. During the grinding process, evenly spray pure water on the grinding paper to keep the grinding surface moist, reduce frictional heat, and prevent overheating and damage to the fiber end face; S7.

5. After each stage of grinding, thoroughly clean the ferrule end face, grinding disc, and sandpaper with pure water to remove residual grinding particles and avoid cross contamination. S7.

6. Carry out the grinding in the order of coarse grinding, medium grinding, fine grinding and polishing, gradually improving the grinding accuracy to ensure that the final end surface is smooth and free of obvious scratches; S7.

7. During the grinding process, regularly check the end surface quality, use a microscope to magnify and observe the end surface condition, and adjust the grinding parameters in time to ensure that the grinding process is under control; S7.

8. After final grinding, use a high-power microscope to inspect the end surface quality to ensure there are no chipping, cracking, or scratches. S7.

9. Clean the end face after grinding. Use a dust-free paper dipped in an appropriate amount of alcohol to gently wipe it to remove any remaining moisture and impurities, ensuring that the end face is clean and tidy.

7. The method for manufacturing a hollow-core anti-resonant optical fiber jumper according to claim 6, wherein: The optical fiber polishing parameters in step S7.3 are as follows: Coarse grinding: Use 600-mesh abrasive paper, grind for 6 minutes, and grind at 75 rpm; Medium grinding: Use 4000 mesh grinding paper, grinding time is 3 minutes, grinding speed is 75 rpm; Fine grinding: Use 8000 mesh abrasive paper, grinding time is 6 minutes, grinding speed is 75 rpm; Polishing: Use 12000 mesh abrasive paper, the grinding time is 10 minutes, and the grinding speed is 75 rpm.

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