Fiber Fusion Splicing Services

Fiber Optic Splicing

For light to travel effectively in optical fibers, it needs a continuous, non-disruptive path to minimize signal loss over long distances. In fiber links spanning hundreds of kilometers, light signals require amplification, cross-connection, and various other processing tasks. As a standard practice, these connections involve joining two fibers together, which can be accomplished using connectors or splicing.

Splicing is the practice of joining two fibers together without using connectors. There are two types of fiber splices: fusion splicing and mechanical splicing. Splicing can be performed during installation or repair.

Splices generally offer lower signal loss and better mechanical integrity compared to connectors, which make system configuration much more flexible. Typically, splices are used to connect fiber cables in outdoor applications, while connectors are used to terminate fiber cables inside buildings.

Fusion Splicing

Fusion splicing is a highly precise method for joining two optical fibers end-to-end, creating a continuous optical path. This technique involves the use of high temperature, typically generated by an electric arc, to melt and fuse the glass ends of the fibers together. For successful fusion splicing, the fiber cores must be precisely aligned to ensure optimal signal transmission with minimal loss.

The process starts with the preparation of the fiber ends, which includes stripping the protective coating, cleaning, and cleaving the fibers to create a flat, smooth surface. Once prepared, the fibers are placed into a fusion splicer, a sophisticated device designed to align the fiber ends with high accuracy.

The fusion splicer then generates an electric arc that heats the fiber tips to a point where they melt. At this moment, the splicer pushes the molten ends together, causing them to fuse into a single fiber. This method creates a splice with very low loss and high mechanical strength, often stronger than the fiber itself.

Fusion splicing is the preferred technique for permanent splices, especially in telecommunications, where signal integrity and reliability are crucial. It offers several advantages over mechanical splicing, including lower insertion loss, lower back reflection, and a higher level of environmental resistance, making it ideal for long-haul fiber optic networks, undersea cable connections, and anywhere where the highest performance is required.

Mесhаnісаl Sрlісіng

Mechanical splicing uѕеѕ mесhаnісаl fixtures to join twо fibers tоgеthеr еnd to еnd (аgаіn, fiber соrеѕ are аlіgnеd precisely). Mесhаnісаl splicing jоіn two fіbеr ends either bу clamping thеm wіthіn a structure оr by gluing them together.  

Sіnglе mоdе fіbеr rеԛuіrеѕ muсh tighter tolerances thаn multіmоdе fіbеrѕ fоr splicing. So ѕресіаl еԛuірmеnt are оftеn rеԛuіrеd for ѕіnglе mоdе mechanical ѕрlісеѕ. Thіѕ mаkеѕ ѕіnglе mоdе fiber mechanical ѕрlісіng much mоrе еxреnѕіvе thаn multіmоdе fіbеr mесhаnісаl ѕрlісіng.

The аdvаntаgеѕ of Mесhаnісаl ѕрlісіng

Mесhаnісаl ѕрlісіng dоеѕn’t need соѕtlу capital equipment tо wоrk, but іt dоеѕ rеԛuіrе hіghеr соnѕumаblе costs. Sо fоr оrgаnіzаtіоnѕ thаt dоn’t mаkе a lot оf ѕрlісіng, mесhаnісаl ѕрlісіng is thе best сhоісе. It іѕ аlѕо bеѕt ѕuіtеd for еmеrgеnсу repairs.

Types оf mechanical ѕрlісіng

• Capillary Type

The capillary type mechanical splicing method involves aligning two optical fibers for effective connection without the need for fusion splicing. In this approach, both fibers are inserted into a slender capillary tube designed with an inner diameter that precisely matches the diameter of the fiber’s cladding. To prepare for insertion, the protective coatings around the fibers must be removed to expose the cladding, which is then meticulously cleaned to ensure optimal light transmission.

At the heart of the capillary tube, the clean and exposed ends of the fibers are carefully advanced towards each other until they touch. To enhance the quality of the splice and minimize optical loss, index matching gels are often applied at the junction where the fiber ends meet. These gels play a crucial role in reducing back reflections, which can degrade the signal quality.

Once the fibers are correctly positioned within the capillary tube, they are secured in place using either compression or friction methods. This securement ensures that the fibers remain aligned, allowing for consistent signal transmission across the splice. Capillary type mechanical splicing is valued for its simplicity and effectiveness, especially in scenarios where quick or temporary splices are required without the need for specialized equipment like fusion splicers.

• The Ribbon V-Groove type mechanical splicing

The Ribbon V-Groove type mechanical splicing method is specifically designed to accommodate the unique challenges presented by splicing multiple fiber cables, such as ribbon fibers. Unlike the capillary type, which is suited for individual fibers, the Ribbon V-Groove method efficiently manages the alignment of multiple fibers simultaneously.

In this approach, a fiber ribbon, which consists of multiple fibers aligned side by side, is placed within a V-shaped groove array. Each fiber within the ribbon is seated in its own V-groove, ensuring precise alignment. The process involves butting two ribbon fibers together within this V-groove array to ensure that all corresponding fibers from each ribbon are accurately aligned.

To secure the splice, a cover plate is applied over the ribbons in the V-groove array. This not only holds the fibers in place but also protects the splice from external environmental factors that could affect its integrity. The Ribbon V-Groove splice offers an effective solution for multifiber splicing, providing a reliable and straightforward method for aligning and joining ribbon fibers.

This splicing technique is particularly valuable in applications requiring the simultaneous splicing of multiple fibers, offering efficiency and reliability. It is widely used in telecommunications and network installations where ribbon fiber cables are prevalent, demonstrating its utility in high-density fiber environments.

• Elastomeric type mechanical splice

The Elastomeric type mechanical splice is a specialized method used predominantly for laboratory testing or emergency repairs of fiber optic cables. This technique bears similarity to the V-Groove type splice in terms of aligning fibers for splicing. However, a distinctive feature of the Elastomeric splice is its use of a single fiber V-groove made from flexible plastic, which allows for a certain degree of pliability during the splicing process.

The procedure begins with the application of an index matching gel into the groove. This gel serves to minimize the optical loss by enhancing the continuity between the two fiber ends and reducing back reflections which could impair signal transmission. Following the application of the gel, one end of a fiber is inserted into the groove until it reaches approximately the halfway point of the channel. Subsequently, the second fiber is introduced from the opposite end of the groove and advanced until it meets the first fiber directly in the middle.

The flexibility of the elastomeric material in the V-groove helps to gently secure the fibers upon contact, ensuring that they are properly aligned and held in place without causing damage to the delicate glass. This elasticity also allows for minor adjustments to be made post-insertion, ensuring optimal alignment and signal integrity.

Given its ease of use and the minimal equipment required, the Elastomeric type splice is particularly useful for quick, temporary repairs or for applications within a laboratory setting where precision and adaptability are paramount. Despite its advantages for temporary fixes or tests, it’s important to consider more permanent solutions for long-term fiber optic infrastructure needs.