PLC Splitter Training
First, PLC Splitter Introduction:
1.1. Overview
1.2. Common index
1.3. Performance parameter
1.4. Classification
Second, Raw Material and Fabrication of PLC Splitter
2.1. Raw material
2.2. Fabrication
First, PLC Splitter Introduction
1.1.Overview

PLC splitter, short for Planar Waveguide Circuit splitter, is used to divide one or two light beams to multiple light beams uniformly or combine multiple light beams to one or two light beams. It is a passive optical device, applied to PON (EPON and GPON in FTTH application) to connect OLT in cerntral office and ONT at the premise.
The configuration of PLC Splitter is 1xN (N=2, 4, 8, 16, 32, 64) and 2xN (N=2, 4, 8, 16, 32, 64).

PLC Splitter Fabrication Technology:
PLC splitter is based on Semiconductor technology of planar waveguide circuit. PLC splitter consists of one optical PLC Splitter chip and several optical arrays depending on the output ports. The optical arrays are coupled on both end of the PLC splitter chip.
1.2.Common index
1.2.1.Insertion loss
insertion loss is the loss of signal power resulting from the insertion of a device in a transmission line or optical fiber and is usually expressed in decibels (dB).
The insertion loss of PLC Splitter is: IL=-10lg Pout/Pin. Pout is the optical power of output power, and Pin is the optical power of input power.
1.2.2.Return loss
Return loss is the loss of power in the signal returned/reflected by a discontinuity in a transmission line or optical fiber. This discontinuity can be a mismatch with the terminating load or with a device inserted in the line. It is usually expressed as a ratio in decibels (dB).
The return loss of PLC Splitter is RL=-10lgPril/Pin. Pril is the optical power, which returns from the device or the system to the input port of PLC Splitter and Pin is the optical power of input power.
1.2.3.Excess loss
Excess loss of PLC Splitter is the optical power loss of the total power of all output ports and that of all input ports and is usually expressed in decibels (dB).
Excess loss represents the quality of manufacturing technology. The lower it is, the better the manufacturing craft is.
1.2.4.Loss Uniformity
Uniformity of insertion loss between ports: the difference value of max. Insertion loss and min. Insertion loss.
Uniformity of insertion loss between wavelengths: for the same port, but different wavelengths, the difference value of max. Insertion loss and min. Insertion loss.
1.2.5.Directivity
Directivity is the ratio of the optical power launched into an input port to the optical power returning to any other input port.
1.3.Performance parameter
Technical parameters with optical connectors in the tender documents from China Telecom in 2012.
Port Configuration | 1x2 | 1x4 | 1x8 | 1x16 | 1x32 | 1x64 | 1x128 |
Fiber Type | G.657A1 | ||||||
Operating Wavelength (nm) | 1260nm~1650nm | ||||||
Max. Insertion Loss (dB) | ≤4.1 | ≤7.4 | ≤10.5 | ≤13.8 | ≤17.1 | ≤20.4 | ≤23.8 |
Loss Uniformity between Ports (dB) | ≤0.8 | ≤0.8 | ≤0.8 | ≤1.0 | ≤1.5 | ≤2.0 | ≤2.0 |
Loss Uniformity between wavelengths (dB) | ≤0.8 | ≤0.8 | ≤0.8 | ≤1.0 | ≤1.0 | ≤1.0 | ≤1.2 |
Return Loss (dB) | ≥50 | ≥50 | ≥50 | ≥50 | ≥50 | ≥50 | ≥50 |
Directivity (dB) | ≥55 | ≥55 | ≥55 | ≥55 | ≥55 | ≥55 | ≥55 |
Port Configuration | 2x2 | 2x4 | 2x8 | 2x16 | 2x32 | 2x64 | 2x128 |
Fiber Type | G.657A1 | ||||||
Operating Wavelength (nm) | 1260nm~1650nm | ||||||
Max. Insertion Loss (dB) | ≤4.4 | ≤7.7 | ≤10.8 | ≤14.1 | ≤17.4 | ≤20.7 | ≤24.1 |
Loss Uniformity between Ports (dB) | ≤0.8 | ≤1.0 | ≤1.0 | ≤1.5 | ≤2.0 | ≤2.5 | ≤2.5 |
Loss Uniformity between wavelengths (dB) | ≤0.8 | ≤0.8 | ≤0.8 | ≤1.0 | ≤1.0 | ≤1.0 | ≤1.2 |
Return Loss (dB) | ≥50 | ≥50 | ≥50 | ≥50 | ≥50 | ≥50 | ≥50 |
Directivity (dB) | ≥55 | ≥55 | ≥55 | ≥55 | ≥55 | ≥55 | ≥55 |
1.4.Classification
1.4.1.Bare Fiber PLC Splitter
The package of Bare Fiber PLC Splitter is stainless steel tube.
The output fibers can be single fiber of 250um or ribbon fibers of 4 fibers or 8 fibers.

1.4.2.Blockless PLC Splitter
The package of Bare Fiber PLC Splitter is stainless steel tube.
The output fibers are 900um loose tube.
Blockless PLC Splitters are usually installed in Fiber Optic Splice Closure, Optical Distribution Box, Splitter Tray, etc.

1.4.3.Fanout PLC Splitter
The package of Fanout Fiber PLC Splitter is stainless steel tube.
The output fibers are ribbon fibers, which connects with ribbon fiber kits and then 900um loose tube.
Fanout PLC Splitters are usually installed in Fiber Optic Splice Closure, Optical Distribution Box, Splitter Tray, etc.

1.4.4.Plastic Box PLC Splitter
The package of Plastic Box PLC Splitter is a plastic cassette.
The output fibers are 2.0mm or 3.0mm cable jacket.
Plastic Box PLC Splitters are usually installed in Splitter Tray, Optical Distribution Box, 19 inch rack mounted patch panel, etc.

1.4.5.Rack Mount PLC Splitter
The package of Rack Mount PLC Splitter is 19 inch rack.
Rack Mount PLC Splitters are usually installed in ODF, network rack, cabinet, etc.

1.4.6.Tray Type PLC Splitter
The package of Tray Type PLC Splitter is plastic splitter tray.
Tray Type PLC Splitters are usually installed Optical Distribution Cabinet.

1.4.7.Insertion Module PLC Splitter
The package of Insertion Module PLC Splitter is plastic insertion module.
Insertion Module PLC Splitters are usually installed Optical Distribution Cabinet, Optical Splitter Box, etc.



Second, Raw Material and Fabrication of PLC Splitter
2.1. Raw material
1 | PLC Splitter Chip | Equally split optical power |
2 | Fiber Array | Couple optical signal |
3 | Stainless Steel Tube | Package of PLC Splitter |
4 | Rubber Boot | Protect fiber cable |
5 | Fiber Optic Connector Parts | Connect fibers |
6 | Fiber Optic Cable | Protect optical fiber |
7 | Plastic Box | Package |
2.1.1. Main PLC Splitter Wafer Manufacturer
Japanese wafer: Furukawa, Hitachi
Korean wafer: Wooriro, Corecross, PPI, FIRA
Other: COLORCHIP

2.1.2. Main PLC Splitter Chip Manufacturer in China
Until 2012, Main PLC Splitter Chip Manufacturer in China are: ACCELINK, SOLOREIN, SHIJIA, HONGHUI, etc.

2.1.3. Fiber Array
There are two key techniques of fiber arrays: high precision V-groove or U-groove and highly reliable glue. The high precision V-groove or U-groove is made of quartz.


2.1.4. Main glue manufacturer
There are UV glue and Fiber Array Assembly glue.
Glue Manufacturers of NTT from Japan, DOWCORNING from USA.
Other raw materials:
Item | Material | Manufacturer of Level A |
Optical Fiber | Silica glass | Corning, YOFC, Hengtong, Fiberhome, SDGI |
Ferrule | High Precision Zirconia (ZrO2) | CHAOZHOU THREE-CIRCLE |
Connector Parts | Plastics of PBT and metal | |
Adapter | Plastic housing of PBT; or metal housing Sleeve: High Precision Zirconia (ZrO2) | Suzhou TFC, Shenzhen Upcera, Yingfeng, Zhizhuo |
2.2. Fabrication
2.2.1. Wafer Cutting

Wafer cutting

Temperature control of Pure water, to wash and cool during wafer cutting

Compressed air to filter oil contamination and moisture

Water purification
2.2.2. Fiber Array

Fiber cutting

Fiber stripping

Assembling

Glue

Heating

Polishing

Endface inspection
2.2.2.Coupling and packaging

Microscope

1550nm light source

Optical power meter

Fiber Optic Fusion Splicer

Coupling

CCD Monitor

UV heating

Electronic dehumidifier
2.2.3. Splitter Assembling and Testing

Vacuum deaerator

Glue injector

Oven

Ultrasonic cleaner

Heat Oven

Polishing machine

Connector Endface Microscope

Temperature circulation box

Insertion and return loss tester

PDL tester