Methods of ferrule reshaping for correcting core-to-ferrule concentricity errors, and optical fiber cable assemblies related to such methods

Patent metadata

Field	Value
Publication number	US-11420293-B2
Application number	US-201916459041-A
Country	US
Kind code	B2
Filing date	Jul 1, 2019
Priority date	May 26, 2016
Publication date	Aug 23, 2022
Grant date	Aug 23, 2022

Abstract

Methods of reshaping ferrules used in optical fiber cables assemblies are disclosed. The reshaping methods reduce a core-to-ferrule concentricity error (E), which improves coupling efficiency and optical transmission. The methods include measuring a true center of the ferrule, wherein the true center is based on an outer surface of the ferrule; and reshaping at least a portion of the ferrule to change the true center of the ferrule, wherein the reshaping includes enlarging a portion of the ferrule. A variety of reshaping techniques are also disclosed.

First claim

What is claimed is:

1. A method for reducing a core-to-ferrule concentricity error for a ferrule having an axial bore sized to operably support an optical fiber having a core, the method comprising:
measuring a true center of the ferrule, wherein the true center is based on an outer surface of the ferrule; and
reshaping at least a portion of the ferrule to change the true center of the ferrule, wherein the reshaping includes enlarging a portion of the ferrule;
wherein the step of enlarging a portion of the ferrule includes forming one or more protuberances on the outer surface of the ferrule.

2. The method of claim 1 , wherein the step of forming one or more protuberances on the outer surface of the ferrule comprises:
creating, on the outer surface of the ferrule, a crater with at least one micro-protuberance on a side of the crater.

3. The method according to claim 2 , wherein a depth of the crater is between 0.1 μm and 1000 μm and a height of the at least one micro-protuberance is between 0.02 μm and 100 μm.

4. The method according to claim 2 , wherein creating the crater and the at least one micro-protuberance includes applying a laser beam to irradiate the outer surface of the ferrule, wherein the laser beam has a wavelength ranging between 10 nm and 20,000 nm and an average power delivered to the ferrule between 0.001 μJ/μm 2 and 1000 μm J/μm 2 , wherein the average power is based on a time period that is between 1 pico-second and 1 second.

5. The method according to claim 4 , wherein the laser beam has a wavelength between 100 nm and 2000 nm and an average power delivered to the ferrule between 0.01 μJ/μm 2 and 100 μJ/μm 2 , wherein the average power is based on a time period that is between 1 pico-second and 1 second.

6. The method according to claim 4 , wherein the laser beam has a wavelength between 150 nm and 1000 nm and an average power delivered to the ferrule between 0.01 μJ/μm 2 and 100 μJ/μm 2 , wherein the average power is based on a time period that is between 1 pico-second and 1 second.

7. The method according to claim 4 , wherein the laser beam has a wavelength between 150 nm and 1000 nm and an average power delivered to the ferrule between 0.01 μJ/μm 2 and 10 μJ/μm 2 , wherein the average power is based on a time period that is between 1 pico-second and 1 second.

8. The method according to claim 4 , wherein the laser beam has a wavelength between 355 nm and 532 nm and an average power delivered to the ferrule between 0.1 μJ/μm 2 and 10 μJ/μm 2 , wherein the average power is based on a time period that is between 1 pico-second and 1 second.

9. The method according to claim 2 , further including mating a sleeve having a sleeve center onto the ferrule, wherein the at least one micro-protuberance engages with the sleeve thereby distributing a force of the sleeve when applied onto the ferrule.

10. The method according to claim 9 , wherein the at least one micro-protuberance engages with the sleeve to reduce an eccentricity of the core relative to the sleeve center.

11. The method according to claim 10 , wherein the step of reshaping includes removing material from the at least one micro-protuberance, wherein the step of removing material includes polishing the at least one micro-protuberance.

12. The method according to claim 2 , wherein the at least one micro-protuberance includes a first micro-protuberance on one side of the crater and a second micro-protuberance on a second side of the crater;
wherein a depth of the crater is between 0.1 μm and 1000 μm and heights of the first micro-protuberance and the second micro-protuberance are between 0.02 μm and 100 μm.

13. The method according to claim 12 , wherein the first micro-protuberance and the second micro-protuberance are positioned opposite each other defining the crater therebetween.

14. The method according to claim 2 , wherein the at least one micro-protuberance includes a cluster of micro-protuberances around the crater;
wherein a depth of the crater is between 0.1 μm and 1000 μm and a maximum height of the cluster of micro-protuberances is between 0.02 μm and 100 μm.

15. The method according to claim 1 , wherein enlarging a portion of the ferrule includes increasing a diameter of the ferrule to a predetermined value.

Assignees

• Corning Optical Communications LLC

Inventors

• Bookbinder Dana Craig
• Lin Boyang
• Piech Garrett Andrew
• Sims Steven Ross
• Sutherland James Scott
• Webb Michael Brian
• Zambrano Elvis Alberto

Classifications

• G02B6/385

  Accessories for testing or observation of connectors (means for centering or aligning the light guide within the ferrule with auxiliary facilities for movably aligning or adjusting the fibre within its ferrule, measuring position, eccentricity G02B6/3843; mechanical features associated with the optical testing of optical fibres G01M11/088) · CPC title

• B23K26/362

  Laser etching · CPC title

• G02B6/3833

  Details of mounting fibres in ferrules; Assembly methods; Manufacture · CPC title

• G02B6/3863 Primary

  fabricated by using polishing techniques (grinding of the fibre ends B24B19/226) · CPC title

• B23K26/0006

  taking account of the properties of the material involved (B23K26/32, B23K26/40 take precedence) · CPC title