Optical fiber assemblies and methods of forming the same
AssigneeCorning Research & Development Corporation
InventorsJames Daniel Blackburn, Xiaole Cheng, John Patrick Lammers, Darrin Max Miller, Stephan Toepper
Life of this patent
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Abstract
Methods of forming an optical fiber assembly involve placing an adhesive in a ferrule assembly, heating the ferrule assembly through thermal induction, inserting an optical fiber into the ferrule bore during or after the heating step, and securing the optical fiber to the ferrule assembly using the adhesive. The thermal induction causes the adhesive to efficiently take or maintain a melted form to allow the optical fiber insertion.
Claims19
A method of forming a plurality of optical fiber assemblies that each include a respective ferrule and a respective ferrule holder, the respective ferrule having a front portion defining a front end, a rear portion defining a rear end, and a ferrule bore extending between the front end and the rear end, and the respective ferrule holder receiving the rear portion of the respective ferrule and together with the respective ferrule defining a respective ferrule assembly, wherein the respective ferrule holder comprises metal and has a ferrule holder passage that communicates with the ferrule bore, the method comprising the steps of:
- placing thermoplastic adhesive in each of the ferrule assemblies, wherein for each of the ferrule assemblies the thermoplastic adhesive is placed in the corresponding ferrule holder passage, the corresponding ferrule bore, or both the corresponding ferrule holder passage and the corresponding ferrule bore;
- positioning the ferrule assemblies relative to a common induction coil so that the ferrule assemblies each reside on a respective axis that extends through the common induction coil;
- heating the ferrule assemblies by causing electrical current to flow through the common induction coil, wherein the electrical current generates a magnetic field that induces heat generation in the respective ferrule holders of the ferrule assemblies to cause the thermoplastic adhesive to take or maintain a melted form;
- for each of the ferrule assemblies, inserting a respective optical fiber into the corresponding ferrule bore during or after the heating step, wherein the temperature of the respective ferrule maintains the thermoplastic adhesive in the melted form during the inserting;
- and
- for each of the ferrule assemblies, securing the respective optical fiber to the respective ferrule using the thermoplastic adhesive, wherein the thermoplastic adhesive solidifies during the securing.
A method of forming a plurality of optical fiber assemblies that each include a respective ferrule and a respective ferrule holder, the respective ferrule having a front portion defining a front end, a rear portion defining a rear end, and a ferrule bore extending between the front end and the rear end, and the respective ferrule holder receiving the rear portion of the respective ferrule and together with the respective ferrule defining a respective ferrule assembly, wherein the respective ferrule holder comprises metal and has a ferrule holder passage that communicates with the ferrule bore, the method comprising the steps of:
- placing thermoplastic adhesive in each of the ferrule assemblies, wherein for each of the ferrule assemblies the thermoplastic adhesive is placed in the corresponding ferrule holder passage, the corresponding ferrule bore, or both the corresponding ferrule holder passage and the corresponding ferrule bore;
- positioning the ferrule assemblies relative to a common induction coil and respective metal sleeves that are each separate from the common induction coil, wherein the positioning results in each of the respective ferrules at least partially residing within the respective metal sleeve, and wherein the positioning results in the respective metal sleeves being positioned between the respective ferrules and the common induction coil;
- heating the ferrule assemblies by causing electrical current to flow through the common induction coil, wherein the electrical current generates a magnetic field that induces heat generation in the respective ferrule holders of the ferrule assemblies to cause the thermoplastic adhesive to take or maintain a melted form, and wherein the respective metal sleeves remain positioned over the front portion of the respective ferrules when causing electrical current to flow through the common induction coil so that the electrical current induces heat generation in the respective metal sleeves;
- for each of the ferrule assemblies, inserting a respective optical fiber into the corresponding ferrule bore during or after the heating step, wherein the temperature of the respective ferrule maintains the thermoplastic adhesive in the melted form during the inserting;
- and
- for each of the ferrule assemblies, securing the respective optical fiber to the respective ferrule using the thermoplastic adhesive, wherein the thermoplastic adhesive solidifies during the securing.
Dependencies are inferred from the claim text.