Apparatus and method for forming an optical fiber device

Abstract

An apparatus for forming an optical fiber device comprising at least one optical fiber includes a mold having a forming surface, means for heating the mold or the optical fiber, and an insert defining at least one optical fiber locator passage for guiding at least one optical fiber toward the forming surface. A method for forming an optical fiber device from at least one optical fiber includes the steps of heating the optical fiber or a forming surface of a mold to a temperature greater than a melting temperature of the optical fiber; advancing the optical fiber into contact with the forming surface of the mold such that a portion of the optical fiber is formed into a shape inversely corresponding to a shape of the forming surface; and withdrawing the optical fiber from the forming surface.

1 . An apparatus for forming an optical fiber device comprising at least one optical fiber, the apparatus comprising: a mold including a forming surface; means for heating the mold or the at least one optical fiber; and an insert defining at least one optical fiber locator passage for guiding at least one optical fiber toward the forming surface. 
   
   
       2 . The apparatus according to  claim 1 , wherein the forming surface exhibits a geometric configuration inversely corresponding to a geometric configuration of an end of the optical fiber device. 
   
   
       3 . The apparatus according to  claim 1 , wherein the means for heating the mold comprises an electromagnetic heating source. 
   
   
       4 . The apparatus according to  claim 1 , wherein the means for heating the at least one optical fiber is an electrical current discharge. 
   
   
       5 . The apparatus according to  claim 1 , wherein at least one of the mold and the insert comprises a material exhibiting a melting temperature greater than a melting temperature of the at least one optical fiber. 
   
   
       6 . The apparatus according to  claim 5 , wherein the material comprises one of titanium and an alloy in which the alloy's principal element is titanium. 
   
   
       7 . The apparatus according to  claim 1 , wherein the insert is removably mated with the mold. 
   
   
       8 . The apparatus according to  claim 7 , wherein the insert defines an optical fiber locator passage configured to accept a plurality of optical fibers. 
   
   
       9 . The apparatus according to  claim 8 , wherein the optical fiber locator passage is configured to accept a plurality of side-by-side optical fibers. 
   
   
       10 . The apparatus according to  claim 7 , wherein the insert defines an oblong optical fiber locator passage in cross-section. 
   
   
       11 . The apparatus according to  claim 7 , wherein the insert defines a plurality of optical fiber locator passages configured to receive a corresponding plurality of optical fibers. 
   
   
       12 . The apparatus according to  claim 1 , further comprising means for cooling the mold. 
   
   
       13 . The apparatus according to  claim 1 , wherein the forming surface of the mold defines a right-angle recess for forming the optical fiber device. 
   
   
       14 . The apparatus according to  claim 1 , wherein the mold is constructed of a combination of two or more parts. 
   
   
       15 . The apparatus according to  claim 1 , further comprising a guide affixed to the mold, the guide defining a recess configured to receive the insert and an optical fiber locator passage leading from the at least one optical fiber locator passage of the insert toward the forming surface. 
   
   
       16 . The apparatus according to  claim 15 , wherein at least one of the mold, the insert, and the guide comprises a material exhibiting a melting temperature greater than a melting temperature of the at least one optical fiber. 
   
   
       17 . The apparatus according to  claim 16 , wherein the material comprises one of titanium and an alloy in which the alloy's principal element is titanium.