Granted Patent B2

US 12,493,147 · App. 17/211,451 · Granted Dec 9, 2025

Inventors: Lei Huang (Glastonbury, CT); Daniel M. Smith (Westerly, RI)

Assignee: Legrand DPC, LLC

G02B6/02042B29D11/00721B33Y80/00C03B37/012C03B37/0253C03B37/027

Abstract

Claims (53)

1 . A method of fabricating an optical fiber, comprising:

fabricating an optical fiber, the optical fiber defining a longitudinal length having a proximal end and a distal end, the optical fiber including:

(i) a first core profile zone defining a first core diameter, the first core profile zone defining a first core longitudinal length dimensioned greater than zero;

(ii) a second core profile zone defining a second core diameter different from the first core diameter, the second core profile zone defining a second core longitudinal length dimensioned greater than zero;

(iii) a first transition zone connecting the first core profile zone to the second core profile zone, the first transition zone defining a first transition zone longitudinal length dimensioned greater than zero;

(iv) a third core profile zone defining a third core diameter different from the first and second core diameters, the third core profile zone defining a third core longitudinal length dimensioned greater than zero; and

(v) a second transition zone connecting the second core profile zone to the third core profile zone, the second transition zone defining a second transition zone longitudinal length dimensioned greater than zero;

wherein the first core profile zone, the second core profile zone, the first transition zone, the third core profile zone, and the second transition zone are formed as a single, continuous fiber;

wherein the first core diameter of the first core profile zone defines a first constant core profile along the first core longitudinal length;

wherein the second core diameter of the second core profile zone defines a second constant core profile along the second core longitudinal length;

wherein the third core diameter of the third core profile zone defines a third constant core profile along the third core longitudinal length; and

wherein an outer diameter of the optical fiber remains constant along an entire length of the optical fiber.

2 . The method of claim 1 , wherein the optical fiber includes a cladding disposed around the first core profile zone, the second core profile zone, the first transition zone, the third core profile zone, and the second transition zone.

3 . The method of claim 2 , wherein the cladding defines the outer diameter between the proximal and distal ends of the optical fiber.

4 . The method of claim 1 , wherein the optical fiber is a glass optical fiber or a plastic optical fiber.

5 . The method of claim 1 , wherein the first transition zone includes a first transition zone core diameter that tapers from the first core diameter of the first core profile zone to a second transition zone core diameter at the second core diameter of the second core profile zone, and wherein the second transition zone includes a second transition zone core diameter that tapers from the second core diameter of the second core profile zone to a third transition zone core diameter at the third core diameter of the third core profile zone.

6 . The method of claim 1 , wherein the first core longitudinal length of the first core profile zone is dimensioned different than the second core longitudinal length of the second core profile zone.

7 . The method of claim 1 , wherein the third core longitudinal length of the third core profile zone is dimensioned different than the first and second core longitudinal lengths of the first and second core profile zones, respectively.

8 . The method of claim 1 , wherein the first transition zone longitudinal length of the first transition zone is dimensioned different than a second transition zone longitudinal length of the second transition zone.

9 . The method of claim 1 , wherein the optical fiber includes a third core profile zone, the first core profile zone including includes a single core and the third core profile zone including includes two or more cores.

10 . The method of claim 1 , wherein the first core profile zone includes a core concentrically positioned relative to a central longitudinal axis of the optical fiber, and the second core profile zone includes a core non-concentrically positioned relative to the central longitudinal axis of the optical fiber.

11 . The method of claim 1 , wherein the first core profile zone includes a core with a first polarization-maintaining level, and the second core profile zone includes a core with a second polarization-maintaining level different from the first polarization-maintaining level.

12 . The method of claim 1 , wherein the first transition zone is fabricated to provide a gradual taper and transition between the first core profile zone and the second core profile zone for physical connectivity of the first core profile zone and the second core profile zone without consideration of optical transmission performance along the first transition zone.

13 . The method of claim 1 , comprising cleaving the optical fiber at or near ends of the first transition zone.

14 . An optical fiber, comprising:

an optical fiber core extending a longitudinal length between a proximal end and a distal end, the optical fiber core including:

(i) a first core profile zone defining a first core diameter, the first core profile zone defining a first core longitudinal length dimensioned greater than zero;

(ii) a second core profile zone defining a second core diameter different from the first core diameter, the second core profile zone defining a second core longitudinal length dimensioned greater than zero;

(iii) a first transition zone connecting the first core profile zone to the second core profile zone, the first transition zone defining a first transition zone longitudinal length dimensioned greater than zero;

(iv) a third core profile zone defining a third core diameter different from the first and second core diameters, the third core profile zone defining a third core longitudinal length dimensioned greater than zero; and

(v) a second transition zone connecting the second core profile zone to the third core profile zone, the second transition zone defining a second transition zone longitudinal length dimensioned greater than zero;

wherein the first core profile zone, the second core profile zone, and the first transition zone, the third core profile zone, and the second transition zone define a single, continuous fiber;

wherein the first core diameter of the first core profile zone defines a first constant core profile along the first core longitudinal length;

wherein the second core diameter of the second core profile zone defines a second constant core profile along the second core longitudinal length;

wherein the third core diameter of the third core profile zone defines a third constant core profile along the third core longitudinal length; and

wherein an outer diameter of the optical fiber remains constant along an entire length of the optical fiber.

15 . The optical fiber of claim 14 , comprising a cladding disposed around the first core profile zone, the second core profile zone, and the first transition zone, the third core profile zone, and the second transition zone.

16 . The optical fiber of claim 15 , wherein the cladding defines the outer diameter between the proximal and distal ends of the optical fiber.

17 . The optical fiber of claim 14 , wherein the first transition zone includes a first transition zone core diameter that tapers from the first core diameter of the first core profile zone to a second transition zone core diameter at the second core diameter of the second core profile zone.

18 . The optical fiber of claim 14 , wherein the first core longitudinal length of the first core profile zone is dimensioned different than the second core longitudinal length of the second core profile zone.

19 . An optical fiber, comprising:

an optical fiber core extending a longitudinal length between a proximal end and a distal end, the optical fiber core including:

(i) a first core profile zone defining a first core diameter, the first core profile zone defining a first core longitudinal length dimensioned greater than zero;

(ii) a second core profile zone defining a second core diameter different from the first core diameter, the second core profile zone defining a second core longitudinal length dimensioned greater than zero;

(iii) a first transition zone connecting the first core profile zone to the second core profile zone, the first transition zone defining a first transition zone longitudinal length dimensioned greater than zero;

(iv) a third core profile zone defining a third core diameter different from the first and second core diameters, the third core profile zone defining a third core longitudinal length dimensioned greater than zero; and

(v) a second transition zone connecting the second core profile zone to the third core profile zone, the second transition zone defining a second transition zone longitudinal length dimensioned greater than zero; and

a cladding disposed around the first core profile zone, the second core profile zone, the third core profile zone, the first transition zone, and the second transition zone;

wherein the first core profile zone, the second core profile zone, the third core profile zone, the first transition zone, and the second transition zone define a single, continuous fiber;

wherein the first core diameter of the first core profile zone defines a first constant core profile along the first core longitudinal length;

wherein the second core diameter of the second core profile zone defines a second constant core profile along the second core longitudinal length;

wherein the third core diameter of the third core profile zone defines a third constant core profile along the third core longitudinal length; and

wherein an outer diameter of the optical fiber remains constant along an entire length of the optical fiber.

Assignments (2)

Continuity (3)

References Cited (64)