Hardened Low Back Reflection Optical Fiber Physical Contacts and Connectors Containing Such Contacts and Method for Making the Same

Abstract

A fiber optic connector for use with a fiber optic network having at least one predetermined operating wavelength is provided. First housing contains at least one optical fiber. The optical fiber has a free end forming a physical contact. The physical contact is coated with a protective film. The optical thickness of the protective film is at least 0.10 of the operating wavelength of the fiber optic network. Preferably, the physical contact is thermally shaped. Also preferably, the optical fiber is attached to a quick connect device forming a termini. The physical contact of the optical fiber can be readily coated with the protective film by placing the termini in a vacuum chamber.

1 . A fiber optic connector for use with a fiber optic network having at least one predetermined operating wavelength comprising:
 a first housing;   the first housing containing at least one optical fiber;   the optical fiber having a free end forming a physical contact;   the physical contact being coated with a protective film; and   the optical thickness of the protective film being at least 0.10 of the operating wavelength of the fiber optic network.   
     
     
         2 . A fiber optic connector as set forth in  claim 1  wherein the optical thickness of the protective film is between 0.25 and 1.00 of the operating wavelength. 
     
     
         3 . A fiber optic connector as set forth in  claim 1  wherein the physical contact is thermally shaped. 
     
     
         4 . A fiber optic connector as set forth in  claim 1  wherein the protective film is primarily AL 2 O 3 . 
     
     
         5 . A fiber optic connector as set forth in  claim 1  wherein the protective film is in the form of a single layer. 
     
     
         6 . A fiber optic connector as set forth in  claim 1  wherein the protective film is in the form of multiple layers. 
     
     
         7 . A fiber optic connector as set forth in  claim 1 , further including a quick connect device; the physical contact projecting from one end of the quick connect device and a portion of the optical fiber projecting from the other end of the quick connect device thereby forming a termini. 
     
     
         8 . A fiber optic connector for use with a fiber optic network having at least one predetermined operating wavelength comprising:
 a first housing;   the first housing containing at least one optical fiber;   the optical fiber having a free end forming a physical contact;   the physical contact being thermally shaped;   the thermally shaped terminus being coated with a thin protective film; the optical thickness of the protective film is equal to or less than twice the operating wavelength of the fiber optic network but is at least 0.10 of the operating wavelength.   
     
     
         9 . A fiber optic connector as set forth in  claim 8  wherein the protective film is primarily AL 2 O 3 . 
     
     
         10 . A fiber optic connector as set forth in  claim 8  wherein the optical thickness of the protective film is between 0.25 and 1.00 of the operating wavelength. 
     
     
         11 . A fiber optic connector as set forth in  claim 8  wherein the protective film is in the form of a single layer. 
     
     
         12 . A fiber optic connector as set forth in  claim 8  wherein the protective film is in the form of multiple layers. 
     
     
         13 . A fiber optic connector as set forth in  claim 8 , further including a quick connect device; the physical contact projecting from one end of the quick connect device and a portion of the optical fiber projecting from the other end of the quick connect device thereby forming a termini. 
     
     
         14 . A method for manufacturing a fiber optic connector comprising:
 providing a length of at least one optical fiber;   the optical fiber having first and second free ends; the first free end forming a physical contact;   attaching a quick connect device to the optical fiber wherein the physical contact projects from one end of the quick connect device and a portion of the optical fiber projects from the other end of the quick connect device thereby forming a termini;   applying a vacuum to the termini; and   coating the physical contact with a protective film while the vacuum is applied.   
     
     
         15 . A method as set forth in  claim 14 , further including thermally shaping the physical contact prior to the application of the vacuum 
     
     
         16 . A method as set forth in  claim 14 , further including isolating the physical contact from the remainder of the optical fiber during coating. 
     
     
         17 . A method as set forth in  claim 14 , further including inserting the termini into a connector housing; and splicing the termini to another optical fiber received in a fiber optic cable. 
     
     
         18 . A method as set forth in  claim 14 , further including providing a plate with protective cover received in a vacuum chamber thereby dividing the vacuum chamber into first and second compartments; inserting the termini into one of the holes so that the physical contact projects into the first chamber; coating the physical contact in the first compartment. 
     
     
         19 . A method as set forth in  claim 18 , further including rotating the plate during coating.