Explosion-Proof Fiber Optic Fusion Splicer

June 15, 2011  -  Under a contract from the US Navy, Aurora Optics has created an automatic fusion splicer using the best method for splicing optical fibers – high voltage electric arc – yet it presents no spark hazard in a vapor-laden environment.  In tests according to MIL-STD-810G, method 511, Aurora’s prototype explosion-proof fusion splicers repeatedly arc-spliced optical fibers without ever igniting the most flammable possible atmosphere. 

All fusion splicers until now have been banned from hazardous environments because of the risk of explosive discharge.  The high voltage arc typically used to weld fibers, at over 1000 C, could easily ignite flammable vapors in the air.  For this reason fusion splicers have not been allowed into areas where aviation fuel is likely to used, such as fueled aircraft, aircraft carrier flight decks, and air base flight lines.  Other forbidden zones include telecom applications such as underground utility tunnels, where explosive methane vapor can accumulate.  This has severely inhibited the maintenance and repair of fiber optic cables, since fusion splicing generally delivers by far the lowest and most stable losses.  The alternatives, mechanical splicing and connectorization, are difficult to perform well in adverse environments, the losses are typically an order of magnitude higher than with fusion splices, and the splices have difficulty surviving environmental stresses afterward.

Aurora’s new explosion-proof splicer for the first time delivers all the benefits of fusion splicing to the most adverse environments, particularly those involving flammable or explosive vapors.  Unlike typical miniature fusion splicers it performs fully automatic three-axis alignments of the fibers for the lowest and most consistent insertion losses on both single mode and multi-mode fibers.  It aligns, splices, and loss-estimates fiber cables from 5.8/125 up to 100/140 um, with typical single mode insertion losses of 0.02 dB.  And the fusion splicer is smaller than any other on the market, automatic or passive v-groove – as small as a digital camera!

Aurora Optics has been creating innovative fiber optic solutions to the most difficult problems since 1986.

For further information contact Aurora Optics, Inc., 7 East Skippack Pike, Broad Axe, PA  19002, tel. 215-646-0690, FAX 215-646-4721, email info@aurora-optics.com. Visit them on the web at http://www.aurora-optics.com .