1. Field of the Invention
This invention relates to optical fiber grating devices, in particular to a method of and apparatus for producing high-quality long-period grating devices with an infrared laser.
2. Description of Related Art
Long-period fiber gratings are used for wavelength-selective filtering of light transmitted through the fiber. They are made by creating periodic perturbations in the fiber, typically with a period 50-1000 microns.
The properties of long-period gratings are directly related to the nature of the perturbations induced in the fiber. Long-period gratings can couple light from the core mode of the fiber into multiple cladding modes, depending on the periodicity and the transverse symmetry of the perturbations. If the perturbation is completely axially-symmetric, the core mode will be coupled only to axially-symmetric cladding modes. This is typically desirable in most of the grating applications because the spectrum of the grating will exhibit a few discreet, non-overlapping loss peaks with low polarization dependence (“clean” spectrum). In contrast, when the perturbations are axially asymmetric, the coupling between the core mode and a large number of asymmetric cladding modes is possible. This can result in unpredictable spectral response with overlapping multiple loss peaks and high polarization dependence.
A few methods exist for making perturbations in a fiber. Traditionally, long-period gratings are produced by exposing a fiber to ultraviolet (UV) light with a pre-determined spatial periodicity. This can be achieved either by scanning a UV laser beam over an amplitude mask or by a point-by-point exposure of the fiber to a focused beam. Although, by using special care, high-quality gratings can be manufactured this way, this method of grating writing is not practical for commercial purposes due to the high cost of the required UV lasers and their poor reliability.
Alternatively, long-period gratings can be made by periodically heating the fiber with an infrared laser beam, usually with a carbon dioxide (CO2) laser. The advantage of the infrared grating writing is the low cost and the long lifetime of CO2 lasers.
The physical mechanism of the grating formation by infrared light is fundamentally different compared to that of the UV writing. The UV radiation is absorbed only in the fiber core, where it interacts with defects of the glass structure and changes the connections between various atoms. In contrast, infrared light is fully absorbed by the fiber cladding, even before it reaches the core. This heats the fiber to very high temperature, when the glass almost melts. The softening of the glass results in a change of stresses induced in the fiber during its manufacturing, which in turn is translated into a perturbation of the refractive index through the photoelastic effect.
A typical grating writing configuration is shown in
Chung and Paek disclose a system for making axially-symmetric gratings with a CO2 laser (Chung and Paek, “Fabrication and Performance Characteristics of Optical Fiber Gratings for Sensing Applications,” Proceedings of IEEE, v. 1, p. 36-42, 2002), shown in
Such system also relies on precise optical alignment of multiple components, which is hard to maintain reliably in a production environment. Since fiber 100 has to overlap precisely with the axis of the beam focused by mirror 208, any deviation of the fiber off the axis will result in the reduction of writing efficiency and the loss of the axial symmetry of the exposure. In particular, due to the typical variations in the fiber's polymer coating thickness from one batch to another (which could be 10-20 microns), the fiber would have to be precisely aligned with the axis before each new grating is written. This will increase the manufacturing time and reduce the repeatability. Moreover, the fiber 100 has to be threaded through the holes in the mirrors 206 and 208, further adding to the manufacturing inconvenience. Finally, a significant portion of the CO2 laser beam 108 is wasted by using the ring aperture 204, which removes the brightest central portion of the beam. In addition, this method is incapable of producing multiple gratings in parallel, which would be a great benefit in mass production.
Thus, it appears that none of the solutions for making long-period fiber gratings is well suited for commercial use. Hence, those skilled in the art have recognized a need for a method of, and apparatus for, writing long-period gratings using an infrared laser, which achieves axially-symmetric fiber exposure, so that the resulting gratings will couple light only to symmetric cladding modes and therefore will have clean spectra with easily controllable peaks and low polarization dependence. The need for a method of, and apparatus for, writing long-period gratings, which are inexpensive and easy to implement; have a minimum sensitivity to the fiber displacement, so that the need for fiber alignment before writing each grating is eliminated; minimize the waste of the infrared laser beam energy; and allow manufacturing of multiple identical gratings in parallel, has also been recognized. The invention fulfills these needs and others.
Briefly, and in general terms, the invention is directed to methods of and apparatuses for producing optical fiber gratings. In one aspect, the invention relates to a method of producing a change in the refractive index of an optical fiber. The method includes directing a plurality of optical writing beams toward the optical fiber such that the axes of the plurality of beams are spaced substantially evenly around the circumference of the optical fiber and are directed substantially perpendicular to the axis of the optical fiber. The method also includes exposing the optical fiber to the plurality of optical writing beams for a time sufficient to heat the fiber to a temperature sufficient to produce a change in the refractive index of the optical fiber.
In another aspect, the invention relates to a method of manufacturing identical long-period gratings in a plurality of optical fibers. This method includes mounting the plurality of optical fibers approximately parallel to each other and providing a single input beam. The method also includes disposing a reflective element in the vicinity of the plurality of optical fibers that is capable of both generating a plurality of optical writing beams from the single input beam and directing the plurality of optical writing beams toward the optical fibers. The method further includes exposing the optical fiber to the plurality of optical writing beams for a time sufficient to heat the fiber to a temperature sufficient to produce a change in the refractive index of the optical fiber along a portion of the optical fiber.
In another aspect, the invention relates to an apparatus for manufacturing a long-period grating in an optical fiber. The apparatus includes a light source that provides an input beam with power sufficient to heat the optical fiber to produce a permanent change in the refractive index of the optical fiber. The apparatus also includes means for directing the input beam as a plurality of distinct optical writing beams toward the optical fiber such that the axes of the plurality of beams is spaced substantially evenly around the circumference of the optical fiber and is directed substantially perpendicular to the axis of the optical fiber. The apparatus further includes means for exposing the optical fiber to the plurality of optical writing beams for a time sufficient to heat the fiber to a temperature sufficient to produce a change in the refractive index of the optical fiber along a portion of the optical fiber.
In yet another aspect, the invention relates to a long-period fiber grating that is manufactured by a process that includes directing a plurality of optical writing beams toward an optical fiber such that the axes of the plurality of beams is spaced substantially evenly around the circumference of the optical fiber and is directed substantially perpendicular to the axis of the optical fiber. The process also includes exposing the optical fiber to the plurality of optical writing beams for a time sufficient to heat the fiber to a temperature sufficient to produce a change in the refractive index of the optical fiber; and varying the exposure of the plurality of optical writing beams along a portion of the optical fiber in a predetermined fashion to form a long-period grating.
These and other aspects and advantages of the invention will become apparent from the following detailed description and the accompanying drawings, which illustrate by way of example the features of the invention.
a illustrates the conventional method of writing long-period gratings with a CO2 laser.
b schematically shows the spatial distribution of the refractive index change induced in the fiber by the conventional CO2 laser writing method.
a shows the transmission spectrum of a long period grating written in the conventional way, according to
b shows the transmission spectrum of a long period grating written using a 120° reflector, according to
According to the present invention, a method of manufacturing axially-symmetric long-period gratings comprises an arrangement, which allows multiple infrared beams to converge on the exposed area of a fiber, in a direction perpendicular or nearly perpendicular to the fiber axis. The absorption of the beams in the fiber cladding uniformly heats the fiber, which translates into an axially-symmetric pattern of the refractive index perturbation. As a result, the long-period gratings produced with this method possess clean transmission spectra, with only a few predictable and polarization-independent loss peaks present. Such high-quality gratings and the method of their manufacturing are useful for production of wavelength-selective filters, for example for flattening the gain spectrum of a fiber amplifier.
At least two opposing writing beams are required, although three or more beams symmetrically striking the fiber will produce much more uniform exposure. Preferably, the writing beams irradiate the fiber simultaneously to provide the best axial symmetry of the heating. Alternatively, the writing beams can be turned on one at a time.
In one configuration of an apparatus for manufacturing optical grating, the infrared beam produced by a laser or another source of radiation is split into multiple beams by a series of beamsplitters or diffractive elements. The beams are then directed onto the fiber at appropriate angles with respect to each other but preferably perpendicular or nearly perpendicular to the fiber axis. In order to produce a sufficiently bright and defined spot on the fiber, the beams can be focused by a single focusing component (such as a convex lens or a concave mirror) placed before the beamsplitters, or by separate focusing components placed used with each individual beam.
In another configuration, the multiple beams are produced by a special reflector placed behind the fiber. For example, in a 3-beam system, this can be easily achieved by using a reflector comprised of two mirrors arranged at 120° with respect to each other. Alternatively, a single curved mirror could be used for the same purpose. The fiber alignment requirements can be tremendously reduced by focusing the laser beam with a cylindrical lens, which produces a narrow field of light perpendicular to the fiber. Multiple long-period gratings can be produced in parallel by placing the fibers next to each other, in front of the reflector.
Referring now to the drawings, wherein the reference numerals denote like or corresponding parts throughout the figures, and particularly to
The wavelength of light is chosen such that the absorption of light in the fiber material is high enough to cause efficient heating of the fiber with the available light power, so that a permanent perturbation of the refractive index can be achieved as a result of such heating, due to either a change in glass structure or stress, or both. To achieve such a change, the glass has to be heated close to its softening point (the temperature at which the glass becomes soft). For example, for a common glass fiber predominantly made of silica, the required temperature is 1000-1500° C. Heating to this temperature could be easily accomplished by a few Watts of focused infrared light with wavelength 2.5-11 microns, since the absorption of silica in this wavelength range is very strong. In the subsequent discussion, the term “infrared beam” will be sometimes used to describe the heating source. However, it is evident that depending on the particular absorbing materials incorporated in the fiber cladding or core, the optimum wavelength may or may not be infrared.
The magnitude and the spatial distribution of the refractive index change produced by the light-induced heating will depend on the chemical composition of the fiber and the thermal properties of its core and cladding. In standard telecom fibers, which have a pure silica cladding and a core slightly doped with germanium, the softening points of both the core and the cladding are very close. This means that heating that softens the cladding will most likely affect the core as well. Therefore, the refractive indices of both the core and the cladding will be changed by such heating. In contrast, in a fiber whose core is doped with boron, the core will soften at much lower temperature than the cladding, so it will be possible under certain conditions to obtain refractive index changes localized only in the core. In any case, the multi-beam writing method provided by the present invention will be effective in producing gratings with axially-symmetric refractive index change distribution.
Because the heat-induced change in the refractive index happens only after a certain threshold temperature is reached, the fiber response is a highly nonlinear function of temperature. Therefore, it is advantageous to heat the fiber with all writing beams at the same time for better axial symmetry of refractive index perturbation 306. If the writing beams are turned on one at a time, a larger number of beams may be required to achieve good axial symmetry of the refractive index perturbation.
Although three writing beams are shown in
Typical long-period gratings are structures with periods 100-500 microns. In contrast, the diameter of a typical writing laser beam is 1-5 mm, which is 10 times larger. The required spatial resolution for writing the gratings can be achieved by passing the beam through an amplitude mask. Recording the grating is then accomplished by simply scanning the writing beam over the mask while irradiating the fiber behind the mask. Alternatively, the required spatial resolution can be achieved by focusing the writing beam and varying the exposure while translating the fiber along its axis, either by changing the intensity of the beam or by changing the speed of the fiber translation.
Focusing the beams can be accomplished by using lenses or curved mirrors.
To further simplify the grating writing arrangement, the beam splitting, steering, and alignment can be performed by a single reflective element 502, as shown in
In order to achieve the best symmetry of fiber heating, it would be advantageous for the writing beams 501a, 501b, and 501c to have identical power. It is clear that if the width of beam 500 is close to fiber 100 diameter (125 microns for typical fibers), the edges of the beam 501a and 501b will have much lower power than the beam center 501c. Therefore, it would be desirable to make writing beam 500 wide, with the width at least 3 times larger than the fiber diameter (>375 microns). On the other hand, beam 500 should be no wider than the half of the grating period, which is ˜50-250 microns, in the direction along the fiber, in order to provide sufficient spatial resolution of fabricating the grating. Therefore, beam 500 has to be much more narrow in the direction along fiber 100 than across it when it strikes the fiber. This could be achieved by using a cylindrical lens 506, which focuses beam 500 into a line perpendicular to the fiber axis. Such focusing will also result in nearly uniform light intensity around fiber 100, so any small misalignment of the fiber will not cause a significant drop of the fiber temperature during the exposure.
Instead of using a “V-groove” reflective element with two flat reflective surfaces 502, one could also use a concave mirror for the same purpose. In this case, distance between the fiber and the mirror would have to be close to twice the focal length of the mirror to collect the light efficiently.
The method of writing axially-symmetric long-period gratings using a reflective element positioned behind the fiber can be easily extended to using more than three writing beams. To do this, the shape of the reflective element would be modified. For example,
It is clear that special care should be taken when choosing the material for making reflective elements such as 502 and 602. Because the reflective surfaces will experience nearly focused high-power laser beams, any absorption of light in these reflectors may cause excessive heating and degradation over time. Therefore, the reflective surfaces must have nearly 100% reflectivity and the bulk material of the reflective elements should have good thermal conductivity to dissipate the heat efficiently. In addition, chemical inertness of the surface would be desirable because the reflective elements could be exposed to high-temperature environment generated near the fiber surface by the infrared beam. For these reasons, solid gold with polished reflective surfaces is an excellent choice for making such reflectors. However, other metals or dielectric coatings may be used as well.
a and 7b illustrate the effectiveness of the reflective elements for making axially-symmetric long-period gratings. Each of the gratings was written in Corning SMF-28 fiber using a 25-W CO2 laser operating at 10.6 micron wavelength. The beam was focused on the fiber with a cylindrical lens, thus creating a narrow line perpendicular to the fiber.
Note that the loss of the grating in
For mass production of gratings, it would be extremely valuable to be able to write a few identical gratings in parallel.
In conclusion, the present invention provides a method of manufacturing long-period fiber gratings with multiple infrared laser beams, in order to achieve axially-symmetric heating of the fiber. The resulting gratings have very low insertion loss and are free from unwanted resonances. This method has low sensitivity to fiber misalignment and allows for writing multiple gratings in parallel.
It will be apparent from the foregoing that while particular forms of the invention have been illustrated and described, various modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited, except as by the appended claims.