Micro Splice Protector Cylindrical Sleeve Epoxy
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Solution Overview
Problem
Conventional splice protectors for optical fibers are too large to fit within modern enclosures like CFP packages, and existing polymer coatings do not provide adequate mechanical protection and reliability, especially for small bend conditions.
Innovation Solution
A micro splice protector featuring a cylindrical sleeve of rigid material, such as stainless steel or fused silica, with an inner diameter only slightly larger than the optical fibers, using epoxy to fill gaps and provide additional strain relief, creating a low-profile, conformal coating that minimizes damage and maintains mechanical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional splice protectors (flexible heat-shrinkable plastic with metal bar) are used, then mechanical protection and reliability are provided, but the diameter and length are too large to fit within CFP package enclosures
Solution Approach 1:
The patent changes the physical parameters of the splice protector by using a rigid cylindrical sleeve with inner diameter only slightly larger than the fiber diameter (e.g., 0.265-0.315 inches for 250 μm fibers), compared to conventional protectors that are much larger. This parameter change enables fitting within CFP enclosures while maintaining protection through the rigid material structure and epoxy embedding
Solution Approach 2:
The patent employs composite material structure combining a rigid cylindrical sleeve (stainless steel or fused silica) with epoxy material. The sleeve provides structural strength and rigidity, while the epoxy provides mechanical bonding and stress distribution, creating a composite protector that achieves both small size and high reliability
2Reliability
If polymer coating is used to protect the splice, then a conformal coating is applied, but adequate mechanical protection and high reliability are not provided, especially for small bend conditions
Solution Approach 1:
The patent uses a cylindrical (curved) sleeve geometry that conforms to the circular cross-section of the fiber bundle. This curved geometry provides uniform mechanical protection around the splice, distributing stresses evenly and preventing the types of localized damage that flat or angular protectors would cause under bending conditions
Solution Approach 2:
The rigid cylindrical sleeve acts as a pre-applied mechanical cushion that protects the splice before environmental stresses occur. The sleeve's rigidity provides immediate structural support, preventing the fiber splice from being damaged by subsequent bending or stress events
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The micro splice protector effectively protects fusion splices from mechanical stress and environmental factors, maintaining low insertion loss and polarization loss even under temperature cycling and bending, suitable for advanced packaging applications.
Implementation Method 1
An epoxy material is introduced into the sleeve so as to flow and fill any gaps between the spliced fibers and the interior surface of the sleeve
Data Source
AI summary
A micro splice protector for a fusion connection between a pair of optical fibers takes the form of a cylindrical sleeve of dimensions similar to that of the fusion splice itself, with an epoxy material used to encase the fusion splice within the sleeve. The sleeve is formed to exhibit an inner diameter only slightly greater than the outer diameter of the optical fibers, with the length of the sleeve typically formed to be only slightly longer than the stripped end terminations of the pair of fibers being spliced together. The cylindrical sleeve is formed of a rigid, but lightweight, material (e.g., stainless steel, fused silica) and an epoxy material is injected into the configuration to fill any gaps between the fusion connection and the inner surface of the sleeve. The result is relatively stiff fusion splice protector that is extremely small in size and well-suited for use in optical component packages where space is at a minimum.