The increased amount of telephony and computer data traffic over single optical fiber lines and the desire to reduce redundancy to decrease capital cost have led to an increased need for high reliability components both in terrestrial and submarine markets. The authors describe a multiclad coupler process which has been used to develop ultra-high reliability couplers suitable for undersea applications. A new packaging process using a new low expansion composite wrap and LCP housing was required to achieve the optical and mechanical stability required. Extensive thermal and mechanical tests of the couplers and packaging materials predict excellent performance over the planned 27 year lifetime of these components.
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