Optical connectors with inorganic adhesives and methods for making the same

Abstract

One embodiment of the disclosure relates to an optical connector. The optical connector may include a ferrule, a waveguide, and an inorganic adhesive composition. The ferrule may include a fiber-receiving passage defining an inner surface. The inorganic adhesive composition may be disposed within the ferrule and in contact with the inner surface of the ferrule and the waveguide. The inorganic adhesive composition may include at least about 50% by weight of metal oxide.

What is claimed is: 
     
       1. An optical connector comprising a ferrule, a waveguide, and an inorganic adhesive composition, wherein:
 the ferrule comprises a fiber-receiving passage defining an inner surface; 
 the inorganic adhesive composition is disposed within the ferrule and in contact with the inner surface of the ferrule and the waveguide; 
 the inorganic adhesive composition comprises at least about 50% by weight of metal oxide; and 
 the inorganic adhesive composition comprises yttria-stabilized zirconia. 
 
     
     
       2. The optical connector of  claim 1 , wherein the ferrule is comprises a ceramic material. 
     
     
       3. The optical connector of  claim 1 , wherein the inorganic adhesive composition is comprises substantially the same material as the ferrule. 
     
     
       4. The optical connector of  claim 1 , wherein
 the ferrule comprises zirconia or yttria-stabilized zirconia. 
 
     
     
       5. The optical connector of  claim 1 , wherein the inorganic adhesive composition further comprises one or more nanostructures of graphene, carbon, silver, gold, platinum, or combinations thereof. 
     
     
       6. The optical connector of  claim 1 , wherein the inorganic adhesive composition comprises at least about 50% by weight of yttria-stabilized zirconia. 
     
     
       7. The optical connector of  claim 1 , wherein:
 the inorganic adhesive composition is characterized by an adhesive CTE α1 that varies by less than about 10×10-6/K over a temperature range from about −50° C. to about 80° C.; 
 the ferrule is characterized by a ferrule CTE α2 that varies by less than about 15×10-6/K over a temperature range from about −50° C. to about 80° C.; and 
 the inorganic adhesive composition is configured such that, over a temperature range from about −50° C. to about 80° C., |α1−α2|≤15×10-6/K. 
 
     
     
       8. The optical connector of  claim 1 , wherein the waveguide comprises an optical fiber. 
     
     
       9. An optical connector comprising a ferrule, a waveguide, and an inorganic adhesive composition, wherein:
 the ferrule comprises a fiber-receiving passage defining an inner surface; 
 the inorganic adhesive composition is disposed within the ferrule and in contact with the inner surface of the ferrule and the waveguide; 
 the inorganic adhesive composition comprises at least about 50% by weight of metal oxide comprising zirconia or yttria-stabilized zirconia; and 
 the inorganic adhesive composition has a CTE in a range of between about 80% and 125% of the CTE of the ferrule over a temperature range from about −50° C. to about 80° C. 
 
     
     
       10. A method for securing a waveguide to a ferrule of an optical connector, the method comprising:
 depositing an inorganic adhesive composition precursor onto the waveguide or into a fiber-receiving passage defining an inner surface of the ferrule; 
 inserting the waveguide into the fiber-receiving passage, such that the inorganic adhesive composition precursor is disposed within the ferrule and in contact with the inner surface of the ferrule; and 
 solidifying the inorganic adhesive composition precursor to form an inorganic adhesive composition, wherein and the inorganic adhesive composition comprises at least about 50% by weight of metal oxide comprising zirconia or ytrria-stabilized zirconia, and wherein the solidification comprises exposing the inorganic adhesive composition precursor to a temperature in a range of from about 200° C. to about 1200° C. 
 
     
     
       11. The method of  claim 10 , wherein the inorganic adhesive composition comprises at least about 50% by weight of zirconia or yttria-stabilized zirconia. 
     
     
       12. The method of  claim 10 , wherein the inorganic adhesive composition precursor comprises a metallic salt, another metal ion containing compound, or combinations thereof in a solvent. 
     
     
       13. The method of  claim 12 , wherein the metallic salt and/or the other metal ion containing compound comprises ions of zinc, tin, aluminum, indium, iron, tungsten, titanium, zirconium, silicon, silicon nitride, boron, boron nitride, copper, silver, yttrium, rare earth ions, or combinations thereof. 
     
     
       14. The method of  claim 12 , wherein the metallic salt and/or the other metal ion containing compound comprises ions of zirconium, yttrium, or both. 
     
     
       15. The method of  claim 12 , wherein the solvent is a polar aprotic solvent. 
     
     
       16. The method of  claim 12 , wherein the inorganic adhesive composition precursor is comprises a sol-gel solution. 
     
     
       17. The method of  claim 10 , wherein the waveguide comprises an optical fiber. 
     
     
       18. A method for securing a waveguide to a ferrule of an optical connector, the method comprising:
 depositing an inorganic adhesive composition precursor onto the waveguide or into a fiber-receiving passage defining an inner surface of the ferrule; 
 inserting the waveguide into the fiber-receiving passage, such that the inorganic adhesive composition precursor is disposed within the ferrule and in contact with the inner surface of the ferrule; 
 solidifying the inorganic adhesive composition precursor to form an inorganic adhesive composition, wherein and the inorganic adhesive composition comprises at least about 50% by weight of metal oxide; and 
 crystallizing the inorganic adhesive composition after the solidification. 
 
     
     
       19. The method of  claim 18 , wherein the inorganic adhesive composition is crystallized by exposure to a temperature in a range of from about 200° C. to about 1200° C. 
     
     
       20. An optical connector comprising at least one waveguide and an inorganic adhesive composition, wherein:
 the inorganic adhesive composition bonds the at least one waveguide to a part of the optical connector;   the inorganic adhesive composition comprises at least about 50% by weight of metal oxide; and   the inorganic adhesive composition comprises yttria-stabilized zirconia.   
     
     
       21. The optical connector of claim 20, further comprising a ferrule that defines at least one longitudinal bore for receiving the at least one waveguide, wherein the part of the optical connector to which the at least one waveguide is bonded by the inorganic adhesive composition comprises the ferrule. 
     
     
       22. The optical connector of claim 21, wherein the at least one longitudinal bore defines at least one inner surface, and at least a portion of the inorganic adhesive composition is disposed within the ferrule and in contact with the at least one inner surface. 
     
     
       23. The optical connector of claim 21, wherein the ferrule comprises a ceramic material, and the inorganic adhesive composition comprises substantially the same material as the ferrule. 
     
     
       24. The optical connector of claim 21, wherein:
 the inorganic adhesive composition is characterized by an adhesive coefficient of thermal expansion (CTE) α1 that varies by less than about 10×10 −6 /K over a temperature range from about −50° C. to about 80° C.;   the ferrule is characterized by a ferrule CTE α2 that varies by less than about 15×10 −6 /K over a temperature range from about −50° C. to about 80° C.; and   the inorganic adhesive composition is configured such that, over a temperature range from about −50° C. to about 80° C., |α1−α2|≤15×10 −6 /K.   
     
     
       25. The optical connector of claim 20, further comprising a connector housing and a ferrule at least partially disposed within the connector housing, wherein the part of the optical connector to which the at least one waveguide is bonded by the inorganic adhesive composition is disposed within the connector housing. 
     
     
       26. The optical connector of claim 25, wherein the ferrule is biased forwardly relative to the connector housing. 
     
     
       27. The optical connector of claim 25, wherein at least a portion of the inorganic adhesive composition is arranged in contact with the ferrule. 
     
     
       28. The optical connector of claim 20, wherein the inorganic adhesive composition further comprises one or more nanostructures of graphene, carbon, silver, gold, platinum, or combinations thereof. 
     
     
       29. The optical connector of claim 20, wherein the inorganic adhesive composition comprises at least about 50% by weight of yttria-stabilized zirconia. 
     
     
       30. The optical connector of claim 20, wherein the at least one waveguide comprises at least one stub optical fiber. 
     
     
       31. The optical connector of claim 20, wherein the at least one waveguide comprises a plurality of optical fibers. 
     
     
       32. An optical connector comprising a ferrule, at least one waveguide, and an inorganic adhesive composition, wherein:
 the ferrule comprises at least one fiber-receiving passage defining at least one inner surface;   the inorganic adhesive composition is disposed within the optical connector and in contact with the at least one waveguide;   the inorganic adhesive composition comprises at least about 50% by weight of metal oxide comprising zirconia or yttria-stabilized zirconia; and   the inorganic adhesive composition has a coefficient of thermal expansion (CTE) in a range of between about 80% and 125% of a CTE of the ferrule over a temperature range from about −50° C. to about 80° C.   
     
     
       33. The optical connector of claim 32, further comprising a connector housing, wherein at least a portion of the ferrule is arranged within the connector housing, and the ferrule is biased forwardly relative to the connector housing. 
     
     
       34. The optical connector of claim 33, wherein at least a portion of the inorganic adhesive composition is disposed within the ferrule and in contact with the at least one inner surface. 
     
     
       35. The optical connector of claim 32, wherein the at least one waveguide comprises at least one stub optical fiber. 
     
     
       36. A method for securing at least one waveguide to an optical connector, wherein the optical connector includes an inorganic adhesive composition precursor deposited into the optical connector, the method comprising:
 inserting the at least one waveguide into the optical connector, such that the inorganic adhesive composition precursor is in contact with the at least one waveguide and with a part of the optical connector; and   solidifying the inorganic adhesive composition precursor to form an inorganic adhesive composition that bonds the at least one waveguide to the part of the optical connector, wherein the inorganic adhesive composition comprises at least about 50% by weight of metal oxide comprising zirconia or yttria-stabilized zirconia, and wherein the solidification comprises exposing the inorganic adhesive composition precursor to a temperature in a range of from about 200° C. to about 1200° C.   
     
     
       37. The method of claim 36, wherein the optical connector comprises a ferrule and a connector housing, at least a portion of the ferrule is arranged within the connector housing, and the ferrule is biased forwardly relative to the connector housing. 
     
     
       38. The method of claim 37, wherein at least a portion of the inorganic adhesive composition precursor is disposed within the ferrule. 
     
     
       39. The method of claim 37, further comprising depositing the inorganic adhesive composition precursor onto the at least one waveguide or into a fiber-receiving passage defining an inner surface of the ferrule. 
     
     
       40. The method of claim 36, wherein the exposing of the inorganic adhesive composition precursor to a temperature in the range of from about 200° C. to about 1200° C. comprises heating the inorganic adhesive composition precursor with a laser. 
     
     
       41. The method of claim 36, wherein the inorganic adhesive composition precursor comprises at least about 50% by weight of zirconia or yttria-stabilized zirconia. 
     
     
       42. The method of claim 36, wherein the inorganic adhesive composition precursor comprises a metallic salt, another metal ion containing compound, or combinations thereof in a solvent. 
     
     
       43. The method of claim 42, wherein the metallic salt and/or the other metal ion containing compound comprises ions of zinc, tin, aluminum, indium, iron, tungsten, titanium, zirconium, silicon, silicon nitride, boron, boron nitride, copper, silver, yttrium, rare earth ions, or combinations thereof. 
     
     
       44. The method of claim 42, wherein the metallic salt and/or the other metal ion containing compound comprises ions of zirconium, yttrium, or both. 
     
     
       45. The method of claim 42, wherein the solvent is a polar aprotic solvent. 
     
     
       46. The method of claim 42, wherein the inorganic adhesive composition precursor comprises a sol-gel solution. 
     
     
       47. The method of claim 36, wherein the at least one waveguide comprises at least one stub optical fiber. 
     
     
       48. A method for securing at least one waveguide to an optical connector, wherein the optical connector includes an inorganic adhesive composition precursor deposited into the optical connector, the method comprising:
 inserting the at least one waveguide into the optical connector, such that the inorganic adhesive composition precursor is in contact with the at least one waveguide and with a part of the optical connector;   solidifying the inorganic adhesive composition precursor to form an inorganic adhesive composition that bonds the at least one waveguide to the part of the optical connector, wherein the inorganic adhesive composition comprises at least about 50% by weight of metal oxide; and   crystallizing the inorganic adhesive composition after the solidification.   
     
     
       49. The method of claim 48, wherein the inorganic adhesive composition is crystallized by exposure to a temperature in a range of from about 200° C. to about 1200° C. 
     
     
       50. The method of claim 48, wherein the optical connector comprises a ferrule and a connector housing, at least a portion of the ferrule is arranged within the connector housing, and the ferrule is biased forwardly relative to the connector housing. 
     
     
       51. The method of claim 50, wherein at least a portion of the inorganic adhesive composition precursor is disposed within the ferrule. 
     
     
       52. The method of claim 50, further comprising depositing the inorganic adhesive composition precursor onto the at least one waveguide or into a fiber-receiving passage defining an inner surface of the ferrule. 
     
     
       53. The method of claim 48, wherein the inorganic adhesive composition precursor comprises a sol-gel solution.