Reducing Heating from Non-Coupled Light in Power Transmitting Optical Fibers

Technical Field

[0001] The invention relates generally to the use of optical fibers for transmission of power, and more particularly to mounting optical fibers for coupling to light sources.

Background

[0002] Optical fibers can be used to transmit power. To transmit along a fiber, electrical power is first converted into light with a power conversion device, such as a multimode pump chip. The high power light is directed into the fiber at a fiber tip, and then travels down the fiber to a destination, or is coupled into another fiber. To achieve optimal coupling at the fiber tip, the fiber tip is accurately aligned with the light source, and, once aligned, securely held in place. A typical securing technique involves stripping a 10-20mm length of the jacket off the fiber at one end, metallizing the exposed glass of the fiber, inserting the fiber through a mounting tube, and securing the fiber to the mounting tube. The mounting tube is then secured to a mounting block.

[0003] High-powered optical fibers have been secured to a mounting tube with a metallic solder applied to the metallized surface of the fiber. When light traveling inside the fiber reaches the fiber wall, a significant portion of the light is deflected out into the metal. The deflected light is rapidly absorbed since the metallized surface of the fiber, as well as the solder, do not transmit light. Furthermore, the interface between the fiber and the solder contains a complex web of oxides and other dielectric materials that also absorb light. Modern multimode power-carrying optical fibers typically carry a total power of about 10 watts. Since about 10% of the fiber's power can be coupled to the metal layer and solder, this coupling can result in the deposition of about one watt within a few millimeters around the solder junction. Such energy deposition can cause intense localized heating, which can

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cause the solder to melt, and thus cause serious damage to the fiber and the surrounding components.

[0004] In one alternative approach, the metallic solder is replaced with glass solder or with epoxy. However, because these materials have a refractive index that is similar to that of glass or even a little higher, they refract light out of the fiber, also causing power loss. Oxides within the glass solder are efficient light absorbers, and the result can again be significant localized heating with potentially destructive consequences.

Summary

[0005] The described embodiments reduce the coupling of power from a power- carrying fiber to its surroundings, particularly the mounting means. This reduction is achieved by securing the fiber with its polymer cladding stripped off to its mount with an adhesive that has a refractive index lower than that of the outer glass cladding of the fiber.

[0006] In general, in one aspect, the invention features a method of mounting an optical fiber for coupling to a light source. The method involves providing a portion of the fiber with its polymer cladding stripped off in a mounting tube, applying an adhesive having a refractive index lower than the refractive index of the fiber core and glass cladding to a junction between the fiber glass cladding and the mounting tube to secure the optical fiber to the mounting tube, and hermetically sealing the mounted fiber and the light source within a module housing. [0007] Embodiments include one or more of the following aspects. The adhesive has a refractive index of less than 1.5; the adhesive may comprise sol gel, and may be transmissive of visible light; the adhesive further may have a curing time of less than 30 minutes at room temperature. The sol gel comprises 3- mercapptopropyl-trimethoxysilane and methyltrimethoxysilane. The mounting tube is mounted such that the optical fiber is aligned with the light source. The mounting tube may be mounted on a mounting block connected to the module housing. The fiber core and cladding may comprise glass, in addition to a polymer outer cladding. Prior to placing the fiber inside the mounting tube, a tip portion of the fiber glass cladding may be exposed by stripping off the polymer cladding.

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[0008] In general, in another aspect, the invention features an apparatus with a mounted optical fiber. The apparatus includes an optical fiber having a tip portion where the fiber with its polymer cladding stripped off is exposed; a mounting tube surrounding at least a portion of the tip portion of the optical fiber, the fiber being secured to the mounting tube with an adhesive having a refractive index lower than the refractive index of glass; and a light source that is optically coupled to the light source.

[0009] Embodiments include one or more of the following aspects. The fiber core is made of glass. The adhesive has a refractive index of less than 1.5; the adhesive curing time is less than 30 minutes at room temperature; the adhesive may be a sol gel adhesive; and the adhesive may be transmissive of light. The mounting tube is mounted so as to align the fiber with the light source. Other features and advantages will become apparent from the drawings and detailed description.

Brief Description of the Drawings

[0010] Figure 1 is a side view of a high power multi-mode laser pump module assembly.

[0011] Figure 2 is an illustration of selected components used to secure a high power optical fiber.

Detailed Description

[0012] Multimode optical fibers typically transmit between one and 10 watts of power as light within an individual fiber, but power transmission may be as high as 100 watts per fiber. The power to be transmitted is normally provided to the fiber as an electrical current traveling along a conducting cable. A high power multimode pump chip converts the incoming electrical energy into optical energy in the form of laser light, which is coupled to an optical fiber. The multimode pump chip, the fiber tip (one end of the fiber), and associated components are all housed within a hermetically sealed module. One source of malfunction in the assemblies that couple electrical signals to optical fibers is leakage of non-coupled energy out of the core of the fiber into the cladding and into other material that is used to adhere the

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end of the fiber to its mount. Such energy leakage can cause intense localized heating with consequent damage to the fiber and its surrounding material, and can cause the system to fail, potentially catastrophically.

[0013J Energy is diverted from a glass fiber when a material surrounding the fiber has a refractive index equal to or higher than that of the fiber's glass, i.e., greater or equal to about 1.4. When glass solder is used to adhere the fiber to a mount, the adhering material has the same or higher refractive index as the fiber, which results in considerable coupling between the light incident on the inner fiber wall and the surrounding material. The degree of coupling may also be affected by the nature of the core-to-glass solder interface, which may have a layer of surface oxides.

[0014] The coupling of light to the surrounding material can be drastically reduced by using a material having a lower refractive index than that of the glass fiber. In this situation, light traveling along the fiber that impinges on the glass/surround boundary is incident from the higher-refractive index side of the junction. If incident at an angle greater than the critical angle (which is typically the case for light traveling along the fiber), the light is internally reflected back into the fiber. Low refractive index surrounding material thus reduces the coupling between the fiber and its surround. [0015] The described embodiment uses a sol gel adhesive, referred to herein as sol gel 1612, to secure the optical fiber to the mounting tube. Sol gel 1612 is a colloidal suspension of silicon dioxide that is gelled to form a solid. It comprises 3- Mercapptopropyl-Trimethoxysilane (MPTMOS), Methyltrimethoxysilane (MTMOS), and Ceramabind 644-A Colloidal Alumina Aqueous Solution. [0016] The following is a typical mixing procedure and sequence.

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1. Weigh 2.5 grams MTMOS into Trace-clean, 2" glass bottle using pipette.

2. Weigh 2.5 grams 644A to same bottle using second pipette.

3. Add 5 drops MPTMOS using third pipette. 4. Screw on lid.

5. Shake by hand for 5 minutes.

6. Allow to rest for 5 minutes.

7. Add 0.75 grams Acetone.

8. Shake bottle. 9. Label bottle contents, batch and mix date.

10. Use or refrigerate.

[0017] The sol gel is an effective adhesive, and serves to replace the metallic solder and/or the glass solder or epoxy adhesives used in other systems. The 1612 compound sol gel has a refractive index of 1.38 at a wavelength of 589 nm, significantly below the 1.5 refractive index of glass.

[0018] Sol gel is also optically transmissive, which means that any light that is coupled into it is not rapidly absorbed and does not cause localized heating. In contrast, the glass used in glass solder contains oxides that are efficient light absorbers that would cause power from coupled light to be deposited close to the contact surface with the fiber core. A further advantage of sol gel is that it is stable at room temperature, having a long shelf life. It also cures relatively rapidly (15 to 30 minutes) at room temperature. This property enables the assembly process to proceed rapidly. It also removes the need for the high temperatures required to melt and apply solder adhesives. This allows the assembly to be fixed while on the assembly station, avoiding possible internal movements within the assembly during removal from the assembly station. The low-temperature cure also beneficially avoids temperatures that could cause other solders in the module to soften or move, which could result in thermal damage to the polymer cladding of the fiber. [0019] In another embodiment, the fiber is adhered to the mount with an adhesive having a refractive index of less than 1.5; in another embodiment, the adhesive has a refractive index of less than 1.45; in yet another embodiment, the adhesive has a refractive index of less than 1.4.

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[0020] Figure 1 is an illustration of a high power, hermetically sealed, multimode pump module that incorporates a sol gel adhesive, and that is used to couple optical power into a fiber. Fiber 102 is mounted inside module 104 with fiber tip 106 aligned with multimode pump chip 108 and its carrier 110. Carrier 110 is mounted on submount 112. Fiber 102 is mounted and secured by ferrule 114, which serves as a mounting tube, and is mounted on mounting block 116. Fiber 102 is adhered to ferrule 114 using a sol gel (not shown in Figure 1). The fiber then passes through second ferrule 118 that exits sealed module 104 through package ferrule 120. First ferrule 114 and second ferrule 1 18 preferably comprise metals or metal alloys. Package ferrule 120 is soldered to wall 122 of module 104, and forms a hermetic seal with wall 122. Fiber 102 is hermetically sealed to second ferrule 118 with a glass solder. The purpose of first ferrule 114 is to secure fiber 102 in correct alignment with multimode pump chip 108, while second ferrule 118 surrounds the fiber with a hermetic seal before it exits sealed module 104. Sealed module 104 includes enclosure 124 containing a gettering material (not shown), which removes impurities from within module 104 through porous housing 126. [0021] Outside sealed module 104, fiber 102 exits second ferrule 118 and, after a short gap, is covered with acrylate fiber jacket 128. The acryl ate jacket is a covering that is normally supplied with the optical fiber, but here, the jacket has been stripped off to expose the glass core of fiber 102 to a distance of 18 ± 0.5mm from fiber tip 106. Second ferrule 1 18 is secured to jacket 128 with notched tube 130, providing strain relief for the fiber gap between second ferrule 118 and jacket 128. The entire assembly from package ferrule 120 to jacket 128 and beyond is covered with protective rubber strain relief boot 132, preferably comprising flamc- retardant rubber.

[0022] Figure 2 is an illustration showing the fiber assembly in more detail. The figure shows the portion of fiber 102 from tip 106 extending about 18mm along the fiber, corresponding to the portion for which fiber 102 has been stripped down to the glass core. At a distance of l-4mm, and preferably at about 2mm, from fiber tip 106, the fiber enters first ferrule 114. The fiber is secured to ferrule 1 14 by sol gel 202, which serves as a low refractive index, highly transmissive adhesive layer. Sol gel 202 is applied to the first ferrule 114, and, through capillary action, wicks along

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fiber 102, reaching approximately 80-100% along the length of ferrule 114. Fiber 102 exits from back face 204 of ferrule 114, and after a short gap of approximately 2mm, enters second ferrule 118, where it is secured with a hermetic seal provided by glass solder 206. Fiber 102 then exits second ferrule 118, and, after short gap 208, enters jacket 128. Strain relief is provided by notched tube 130, which is secured by epoxy joints 210 to second ferrule 118 at one end and to fiber jacket 128 at the other.

[0023J Glass solder is used to secure fiber 102 to second ferrule 118 in order to provide a hermetic seal. This joint allows light to leak from the glass cladding into the glass solder adhesive, which causes heating around the hermetic seal. This heating can be tolerated for low power parts in the 1 OW range since the heat can be dissipated in the seal vicinity without destabilizing the fiber coupling or compromising the hermetic seal. However, when used with high power modules, such light leakage could cause destructive heating. In such applications it would be desirable to use a low refractive index adhesive, such as sol gel, to provide the required hermetic seal at this joint (as for first ferrule 1 14) without the light leakage and resulting heat dissipation associated with a glass solder joint. [0024] Typical applications of optical fibers transmitting high power multimode laser light include ordnance initiation, soldering, photodynamic therapy, and marking. The laser light may also be used to provide pump power to other lasers, such as to diode-pumped solid state lasers, or to fiber lasers. Since the packages are fully hermetic, they can be used in challenging environments, such as underwater or in space.

Other embodiments are within the following claims.

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System and Method for Built-in Testing of a Fiber Optic Transceiver

Cross Reference to Related Applications

[0025] This application claims the priority under 35 U.S. C. § 119(e) of US Provisional Application No. 60/834,256, filed July 28, 2006.

Statement as to Federally Sponsored Research

[0026] This invention was made with Government Support under Contract Number NOOOl 14-05-M-0229 awarded by the U.S. Navy. The Government has certain rights in the invention.

Technical Field

[0027] This invention relates to the testing of optical fibers.

Background

[0028] Fiber optic communication systems can be used to transport data in systems that have components that are packed into tight configurations. For example, in an aircraft space is at a premium, and, as a result, hardware is often packed into the airfirame in a manner that provides little access for maintenance.

When a system failure occurs, it can be difficult to pinpoint the location of the fault because potential failure sites are inaccessible. It may then be necessary to perform cumbersome, time-consuming, and expensive dismantling of equipment in order to gain access to and inspect potential equipment that may be the source of the failure.

Summary

[0029] The described embodiments feature systems and methods of testing a fiber optic transceiver. A test system is interposed between a transmitting laser and an optical fiber. The test system directs a beam of test radiation into the fiber by reflecting the test beam off a coated glass plate. If a defect is present within the

fiber, the test beam is partially or wholly reflected back long the fiber. A second glass plate disposed between the first glass plate the directs the reflected beam to a photo-detector. Measurement of a time delay between the emission of the beam of test radiation and detection of a corresponding reflection of the test beam at the detector is used to determine where the defect is located. The strength of the reflection can be used to determine the nature of the defect.

Brief Description of the Drawings [0030] Figure 3 is a schematic diagram of a built-in test system for a fiber optic transceiver.

[0031] Figure 4 is a solid model illustration of a fiber optic transceiver containing built-in test capability.

[0032] Figures 5 and 6 are two views of a solid model illustration of a fiber optic transceiver containing built-in test capability.

[0033] Figure 7 is a schematic diagram of a built-in test system retrofitted to a fiber optic transceiver.

Detailed Description [0034] The described embodiments include systems and methods of testing and detecting faults in optical fibers and fiber optic transceivers without the need to access the fiber or transceiver or perform visual inspection. The ability to provide such "built-in" testing can avoid the need to perform costly dismantling of buried components during the course of troubleshooting. Optical fibers are fragile structures, and they can partially or wholly fail when they are mechanically ruptured, or even suffer minor impact or strain, such as crimping. This problem is especially a concern when a fiber is operated in a high power mode, such as by a multimode pumped chip. i

[0035] Figure 3 is a schematic illustration of a built-in testing system for a fiber optic transceiver. An unmodified transceiver is represented by an 850 run VCSEL (vertical cavity surface emitting laser) 1102, which is in optical communication with optical fiber 1 104 via lenses 1106 and 1108, as indicated by outgoing transceiver

laser beam 1110. The built-in test feature described herein is shown in box 11 12. A second VCSEL 1 1 14 that emits at a wavelength different from the wavelength emitted by laser 1102 is provided for the purpose of performing the built-in test. Laser 1114 is a 640 nm wavelength laser in this example. It can be desirable for laser 1 114 to provide radiation in the visible range so that if a technician performs a visual inspection of the system, he or she can see the beam of laser 11 14. Two coated glass plates 1 118 and 1120 are aligned at an angle, such as 45 degrees, to the direction of laser beam 1 110 from laser 1102 to fiber 1104. First plate 1118 is coated on both sides with a coating that has a relatively low reflectivity at the wavelength of laser 1102 (in this example, 850 nm), but a relatively high reflectivity at the wavelength corresponding to test laser 1114, i.e., at about 640 nm. Second plate 1 120 is coated on both sides with a coating that, like first plate 1 118, has relatively low reflectivity at 850 nm, but unlike first plate 1 118, has a 50% reflectivity at 640 nm. While this embodiment uses glass plates 1118 and 1120, other sizes, shapes, and compositions of blocks could be used.

[0036] To determine if the fiber communication has developed a fault, such as a mechanical fault, crack, or other defect 1122 in optical fiber 1104, the test laser 1114 is activated. Outgoing beam 1124 from test laser 11 14 is collimated by lens 1126, reflects off first glass plate 1118, and travels through second glass plate 1120, where, after 50% attenuation, it enters fiber 1 104. When outgoing test beam 1 124 reaches fiber defect 1122, at least a part of the outgoing beam is reflected as returning test beam 1 128. Returning beam 1128 travels back along fiber 1104, partially reflects off the surface of second plate 1120, and is directed through lens 1130 to photodetector 1132. Photodetector 1132 converts return beam 1128 into a corresponding electrical signal, which travels to a diagnostic system along a low bandwidth electrical data connection (not shown).

[0037] A timing delay between the emission of outgoing test beam 1124 from test laser 1 114 and the receipt of return beam 1128 at photodetector 1132 indicates the location of fiber defect 1122. The strength of return beam 1128 gives an indication of the nature of defect 1122. A strong return beam with a steep onset profile suggests a clear break or mechanical defect. By contrast, a weak return beam may indicate a partial break, or a strain on the fiber sufficient to cause a change in

the fiber's refractive index near the affected portion of the fiber. In addition, multiple return signals may indicate multiple problem areas at different locations along fiber 1104. If there is no defect in fiber 1104 anywhere between the transceiver and the adjacent transceiver at the other end of fiber segment 1104, the timing and nature of the return pulse (if any) will correspond to a return signal emanating from the transceiver at the other end of fiber segment 1 104, thus signaling that the fault is not to be found in fiber segment 1 104. [0038] The above built-in test may thus enable a diagnostic system to pinpoint the location of a fault without the need to physically access any components. Once the suspected failure site has been identified, a maintenance technician can target repair efforts to the identified component(s).

[0039] Figure 4 is a solid model illustration of an implementation of a transceiver package that contains a built-in test capability. The subassembly depicted inside the housing is illustrated in more detail in Figures 5 and 6. VCSEL 1102 is mounted on ceramic substrate 1302; the beam from VCSEL 1 102 is collimated by lens 1106, and passes through cubes 1304 and 1306, made of a transparent material such as glass, into the optical fiber (not shown). Plates 1402 and 1404 (Fig. 6), made of a transparent material such as glass, are functionally equivalent to first plate 1118 and second plate 1120 respectively (Fig. 3). Plates 1402 and 1404 are embedded within cubes 1304 and 1306. Test laser 1 114 is mounted on ceramic substrate 1308, and is collimated by lens 1114. The outgoing beam from test laser 1114 (not shown) enters glass cube 1304, is deflected through 90 degrees by embedded plate 1402 towards glass cube 1306, and enters the fiber optic (not shown) to the right of cube 1306. If the outgoing beam encounters a defect in the fiber, the beam reflects off the defect, travels back along the fiber, enters cube 1306, and is deflected by embedded plate 1404 into a lens (not shown) and reaches photodetector 1132. The entire assembly is mounted on ceramic substrate 1310 which carries electrical signals between the various components, including photodetector 1132. The ceramic substrate is mounted on a thermoelectric cooler comprising top plate 1312, bismuth telluride columns 1314, and a bottom plate 1316.

[0040] The built-in test systems described above are generally contained within a transceiver package. However, built-in test capability can also be retrofitted to an existing, non-self-testing transceiver without the need to disturb the transceiver package. Figure 7 illustrates a retrofitted built-in test system. Transceiver 1502 is connected to incoming fiber 1504 and outgoing fiber 1506. Retrofitted built-in test module 1508 is inserted across incoming fiber 1504 and outgoing fiber 1506 without affecting transceiver 1502. Built-in test module 1508 contains the same components as described above, including test laser 1114, first glass plate 1118, second glass plate 1 120, and photodetector 1132. [0041] Having described certain embodiments, it should be apparent that modifications can be made without departing from the scope. The specific lasers and wavelengths are examples and other devices with other characteristics can be used. While one expected benefit is the ability to test optical fiber devices with limited access for testing and maintenance, the system does not have to be used with such a device.

[0042] Other embodiments are within the following claims.