Abstract: A ferrule mold having a reverse-image of a through-hole array for optical fibers is formed. A non-polymeric ferrule material is deposited in the reverse-image mold, followed by removing the mold to create a multi-fiber connector ferrule having at least two fiber through-holes. An optical fiber is inserted in each through-hole until each fiber endface is positioned approximately even with a connection surface of the ferrule. A fiber recess for each of the optical fibers is formed such that each fiber is recessed from the multi-fiber ferrule connection surface by a distance of at least 0.1 micron. The recess may be formed by differential polishing of the non-polymeric ferrule and endfaces of the optical fibers. Alternatively, a layer of spacer material may be deposited over the multi-fiber ferrule connection surface. An antireflection coating is deposited over the ends of the recessed fibers.

Abstract: A ferrule mold having a reverse-image of a through-hole array for optical fibers is formed. A non-polymeric ferrule material is deposited in the reverse-image mold, followed by removing the mold to create a multi-fiber connector ferrule having at least two fiber through-holes. An optical fiber is inserted in each through-hole until each fiber endface is positioned approximately even with a connection surface of the ferrule. A fiber recess for each of the optical fibers is formed such that each fiber is recessed from the multi-fiber ferrule connection surface by a distance of at least 0.1 micron. The recess may be formed by differential polishing of the non-polymeric ferrule and endfaces of the optical fibers. Alternatively, a layer of spacer material may be deposited over the multi-fiber ferrule connection surface. An antireflection coating is deposited over the ferrule connection surface and ends of the recessed fibers.

Abstract: An optical fiber connector component that is useful for joining and connecting fiber cables, particularly in the field. A joinder component includes a fiber ferrule coaxially housing a short section of optical fiber with a rearward flanged sleeve that allows the fiber to extend through it. Rearwardly the flanged sleeve extends into a connector body where a fusion splice of the fiber section to the main fiber cable is hidden. Forwardly, the fiber facet and ferrule have anti-reflection coatings and are configured so that the fiber has an output facet recessed slightly relative to the forward polished end surface of the ferrule so that when two ferrule end surfaces are brought together in an adapter, respective fiber facets are slightly spaced apart thereby avoiding wear on fiber facets due to physical contact, yet having good optical communication.

Abstract: Integrated optical devices in which one or more optical fibers are vertically integrated with other optical components in a multilayer arrangement. Optical components include lenses, etalons that may be passive or actuable, WDM filters and beamsplitters, for example. One vertically integrated optical device comprises a fiber socket layer comprising a plurality of sockets including a first socket and second socket arranged proximate to each other, and a lens that has a central axis offset from the cores of the first and second fibers. Optical devices include filters, variable optical attenuators, and switches, for example. A component layer may comprise a spacer layer that provides a predetermined opening that is hermetically sealed to protect sensitive components, such as MEMS devices. Also, a method of forming a socket layer using a two-sided etching process is disclosed. Furthermore, an integrated laser device is disclosed that includes a laser layer.

Abstract: The disclosed hybrid microlens enables the economical production of large diameter, high numerical aperture refractive microlens by microfabrication. The hybrid microlens has a combination of a refractive microlens formed on a thin layer of high index material such as silicon and a spacer layer of a low index material such as fused silica. Advantages include substantially reduced lens sag, fast etching of the microlens, small wafer stack thickness, large diffraction angle in the low index spacer, large optical beam diameter, high optical performance, and low cost. Also disclosed is a design for substantially reduced optical return signal and small polarization dependent optical loss from an optical fiber which is perpendicular to and butt-coupled to a planar optical surface. This design is to form a small slanted surface on the planar optical surface in the vicinity of the optical fiber core and fill the space between the fiber and the slanted surface with an index-matching optical epoxy.