Abstract: An assembly for coupling light between a fiber optic cable connector and optoelectronic devices in an optoelectronic transceiver and method of fabricating the same. An Electric Discharge Machining process shapes and precisely dimensions several slots and alignment holes in a bulkhead. Several very small spherical refractive lenses are picked up and placed into each slot by a vacuum tool. Since the intake cavity at the working end of the vacuum tool has the same width and length as does each of the slots, the spherical lenses are placed in the slots precisely as picked up in the intake cavity. The spherical lenses are then secured in the slots by a coining process, which involves a force applied to a soft metal portion of the bulkhead. Under the action of the applied force, the soft metal around the spherical lenses deforms, thus embedding the spherical lenses in the slots.

Abstract: An integrated and modular coupling module for coupling light between optical devices, such as an optical fiber connector and optoelectronic device, is presented. In this invention, beam-shaping elements and alignment elements are integrated on a single alignment plate in such a way that they maintain a precise physical relationship. The relative physical arrangement between the beam-shaping elements and the alignment elements are configured such that once the alignment elements are engaged with the peripheral devices, accurate optical alignment between the peripheral devices and the coupling module is also attained. The optical coupling module of the present invention enables it to withstand temperatures of 220° C. or higher while maintaining its integrity and performance. The principle of the present invention can also be extended to constructing coupling modules for coupling other types of electromagnetic radiation.