Routable Splice Protector for Optical Fiber Fusion Joints
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Solution Overview
Problem
Conventional splice protectors for optical fiber fusion splices are bulky, inflexible, and time-consuming to apply, and they impose significant mechanical loads on the splice joint, which can lead to geometric distortion and reduced reliability over varying temperatures.
Innovation Solution
A compact, bend-resistant splice protector with a tubular shape and a thermoplastic hotmelt material encapsulation that minimizes mechanical loads and maintains the optical integrity of the fusion splice, featuring a length of 3 to 5 mm and a design that allows for easy passage of pre-coated optical fibers, with a thermoplastic material that adheres to the polymer coatings without delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional splice protectors are used to protect fusion splices, then the splice joint is protected from environmental conditions, but the splice protector is bulky and imposes significant mechanical loads on the splice joint causing geometric distortion
Solution Approach 1:
The splice protector is segmented into a tubular body with an internal cavity that receives the splice joint, allowing the protective function to be separated from the load-bearing function. The tubular structure provides protection while the internal cavity design reduces mechanical constraints on the splice joint.
Solution Approach 2:
The splice protector employs a thin-walled tubular structure that provides environmental protection through its shell form, reducing the overall bulk and mechanical load on the splice joint while maintaining protective functionality.
2Reliability
If conventional splice protectors are used to protect fusion splices, then the splice joint is protected, but the splice protector is inflexible and time-consuming to apply
Solution Approach 1:
The splice protector transitions from a rigid conventional structure to a more dynamic design with a tubular shape and open ends, allowing flexible insertion of the splice joint and adaptation to different routing configurations.
Solution Approach 2:
Instead of enclosing the splice joint completely from the start, the tubular structure with open ends allows the splice to be inserted first, then protected, reversing the conventional approach and reducing application time.
3Reliability
If conventional splice protectors are used, then the splice joint is protected, but they impose significant mechanical loads that lead to geometric distortion and reduced reliability over varying temperatures
Solution Approach 1:
The tubular structure with optimized wall thickness and internal cavity dimensions changes the mechanical parameters of the splice protector, reducing thermal expansion effects and mechanical constraints on the splice joint across temperature variations.
4Adaptability or versatility
If a compact splice protector is used to reduce mechanical loads, then flexibility and routing capability are improved, but protection effectiveness may be reduced
Solution Approach 1:
The splice protector uses a composite structure combining a tubular body material with appropriate mechanical properties, providing both compact size for flexibility and sufficient protection effectiveness through material selection and structural design.
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 solution provides enhanced mechanical properties and reduced macrobend loss, allowing for flexible fiber routing in tight spaces without the need for expensive bend-insensitive fibers, while maintaining optical performance across a wide temperature range.
Implementation Method 1
thermoplastic hotmelt material encapsulation
Implementation Method 2
thermoplastic material that adheres to the polymer coatings
Data Source
Figure 1~2B
Figure 3~4
Figure 5A~5D
AI summary
The present disclosure relates to various types of optical fibers that are spliced together with a splice protector provided to house the spliced optical fibers. The splice protector has dimensions that enable improved mechanical properties of the spliced optical fiber.