Micro Splice Protector

Abstract

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 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. An epoxy is injected into the configuration to fill any gaps between the fusion connection and the inner surface of the sleeve. The result is a relatively stiff fusion splice protector that is small in size and well-suited for use in optical packages where space is at a minimum.

What is claimed is: 
     
         1 . A micro splice protector for encasing a fusion splice connection between a pair of optical fibers, the micro splice protector comprising
 a cylindrical sleeve of rigid material disposed over to encase a fusion splice, the cylindrical sleeve having an inner diameter slightly greater than the output diameter of the pair of optical fibers and a length sufficient to extend beyond stripped end terminations of the pair of optical fibers; and   epoxy material disposed within the cylindrical sleeve so as to surround the stripped end terminations of the pair of optical fibers and the fusion splice, filling remaining space within the cylindrical sleeve.   
     
     
         2 . The micro splice protector as defined in  claim 1  wherein the micro splice protector further comprises
 a first epoxy coating disposed at a first end termination of the cylindrical sleeve to provide a smooth transition between a first optical fiber of the pair of optical fibers and the cylindrical sleeve; and 
 a second epoxy coating disposed at a second end termination of the cylindrical sleeve to provide a smooth transition between a second optical fiber of the pair of optical fibers and the cylindrical sleeve. 
 
     
     
         3 . The micro splice protector as defined in  claim 1  wherein the inner diameter of the cylindrical sleeve is no more than about 50 μm greater than the outer diameter of the pair of optical fibers. 
     
     
         4 . The micro splice protector as defined in  claim 1  wherein the cylindrical sleeve comprises a rigid aluminum sleeve. 
     
     
         5 . The micro splice protector as defined in  claim 1  wherein the cylindrical sleeve comprises a rigid sleeve of fused silica. 
     
     
         6 . The micro splice protector as defined in  claim 1  wherein the cylindrical sleeve comprises a rigid material selected from the group consisting of: metals, ceramics, metal matrix composites (MMCs). 
     
     
         7 . The micro splice protector as defined in  claim 1  wherein the cylindrical sleeve comprises polished end terminations to minimize damage to optical fibers during insertion. 
     
     
         8 . The micro splice protector as defined in  claim 1  wherein the cylindrical sleeve comprises a polished inner surface to minimize damage to optical fibers during fabrication. 
     
     
         9 . A protected fusion splice configuration comprising:
 a first optical fiber having a first predetermined outer diameter, the first optical fiber formed to include a end termination stripped to expose a cladding layer, the end termination defining a first optical fiber endface and having a diameter less than the first predetermined outer diameter;   a second optical fiber having a second predetermined outer diameter, the second optical fiber formed to include a end termination stripped to expose a cladding layer, the end termination defining a second optical fiber endface and having a diameter less than the second predetermined outer diameter;   a fusion splice formed to join the first and second optical fiber endfaces;   a cylindrical sleeve of rigid material disposed over the first and second optical fibers in the region of the fusion splice, the cylindrical sleeve having an inner diameter slightly greater than the outer diameter of the first and second optical fibers and a length sufficient to encase the fusion splice and the stripped end terminations of the first and second optical fibers; and   epoxy material disposed within the cylindrical sleeve so as to surround the fusion splice location and the stripped end terminations of the first and second optical fibers in a manner that fills gaps between the fused first and second optical fibers and an interior surface of the cylindrical sleeve.   
     
     
         10 . The protected fusion splice configuration as defined in  claim 9  wherein the length of the cylindrical sleeve is selected to further encase a small extent of non-stripped sections of the first and second optical fibers. 
     
     
         11 . The protected fusion splice configuration as defined in  claim 10  wherein the protected fusion splice configuration further comprises
 a first strain relief epoxy coating disposed over a first end termination of the cylindrical sleeve and an adjacent portion of the first optical fiber; and 
 a second strain relief epoxy coating disposed over a second, opposing end termination of the cylindrical sleeve and an adjacent portion of the second optical fiber. 
 
     
     
         12 . The protected fusion splice configuration as defined in  claim 9  wherein the first outer diameter of the first optical fiber is essentially the same as the second outer diameter of the second optical fiber. 
     
     
         13 . The protected fusion splice configuration as defined in  claim 12  wherein the inner diameter of the cylindrical sleeve is no more than 50 μm greater than the first outer diameter of the first optical fiber. 
     
     
         14 . The protected fusion splice configuration as defined in  claim 9  wherein the first outer diameter of the first optical fiber is less than the second outer diameter of the second optical fiber. 
     
     
         15 . The protected fusion splice configuration as defined in  claim 14  wherein the inner diameter of the cylindrical sleeve is no more than 50 μm greater than the second outer diameter of the second optical fiber.