Abstract: An expanded beam ferrule includes a first ferrule halve having reflective surfaces and a second ferrule halve, which together retain optical fibers. The reflective surfaces output light perpendicular to the mid-plane of the ferrule. A sleeve aligns the external surface of two similar ferrules, with the reflective surfaces of the respective ferrules facing each other. Output light from an optical fiber held in the first ferrule is bent and collimated by a reflective surface, transmitted to the facing reflective surface in a second ferrule aligned by the sleeve, which bends the light to input to the optical fiber held in the second ferrule. The ferrule components and/or sleeve are precision formed by high throughput metal stamping. The ferrule is incorporated in an optical fiber connector.

Abstract: A composite structure includes a base and an auxiliary portion of dissimilar materials. The auxiliary portion is shaped by stamping. As the auxiliary portion is stamped, it interlocks with the base, and at the same time forming a desired structured feature on the auxiliary portion, such as a structured reflective surface, an alignment feature, etc. With this approach, relatively less critical structured features can be shaped on the bulk of the base with less effort to maintain a relatively larger tolerance, while the relatively more critical structured features on the auxiliary portion are more precisely shaped with further considerations to define dimensions, geometries and/or finishes at relatively smaller tolerances. The auxiliary portion may include a composite structure of two dissimilar materials associated with different properties for stamping different structured features.

Abstract: A ferrule for an optical fiber connector has an external surface for alignment with a complementary surface of an alignment sleeve (i.e., the inside surface of a generally cylindrical or tubular sleeve). The external surface of the ferrule is generally cylindrical, having a sectional contact surface profile that is generally oval in shape. More specifically, a plurality of points of contact between the ferrule and the sleeve are defined along a curve in cross-section, wherein the center of curvature at each of the contact points along this contact point curve (i.e., the curve containing contact points that contribute to alignment) does not lie in the plane of the axis of the array of optical fibers.

Abstract: The present invention provides a spring bias that is particularly suited for use to preload a low profile ferrule of an optical connector. In accordance with the present invention, an axial preload is applied to a connector ferrule by a spring structure provided external of the connector. In one embodiment, spring structure is provided outside a plurality of optical fiber connectors, which provides axial preload of multiple ferrules. Each ferrule could be of the type that supports a plurality of optical fibers of a fiber cable. In one embodiment, the spring bias is effected by a planar flexure external of the connector. The ferrule is coupled to the planar flexure with its longitudinal axis through the center of the planar flexure.

Abstract: An expanded beam ferrule includes a first ferrule halve having first reflective surfaces and a second ferrule halve having second reflective surfaces, which together retain optical fibers. The pair of reflective surfaces output collimated light parallel to the mid-plane of the ferrule. An external sleeve aligns the external surface of two similar ferrules, with corresponding second reflective surfaces of the ferrules facing each other. Output light from an optical fiber held in one ferrule is bent twice by the pair of reflective surfaces, with beam divergence after the first bent, and collimation after the second bent. The collimated light is transmitted to the facing second reflective surface in a facing second ferrule aligned by the sleeve, which is subject to optical reshaping in reverse to that undertaken in the first ferrule, so as to converge and focus light to input to the optical fiber held in the other ferrule.

Abstract: A Mux/Demux subassembly includes a stamped optical bench, which includes an array of stamped reflective surfaces for redirecting optical signals. Alignment features and components of the Mux/Demux subassembly are integrally formed on a stamped optical bench, defining a desired optical path with optical alignment at tight tolerances. The optical bench is formed by stamping a malleable stock material (e.g., a metal stock), to form precise geometries and features of the optical bench.

Abstract: A wall plate is provided having a built-in modem on the backside of the wall plate that performs O/E, E/O and protocol conversions. The backside of the wall plate has an optical port for connecting an end of an optical fiber cable to the wall plate. A printed circuit board (PCB) disposed on the backside of the wall plate has electrical circuitry mounted thereon that performs protocol conversion and communicates with an optical transceiver module also mounted on the PCB. The optical transceiver module receives optical signals transmitted to the customer premises and transmits optical signals from the customer premises and performs O/E and E/O conversion. A front face of the wall plate has at least one socket therein for connection with an electrical connector disposed on an end of an electrical cable. The wall plate does not require a separate power supply.

Abstract: Optical alignment of optical subassembly and optoelectronic device is achieved using an external source and an external receiver, passing optical signal through a passive waveguide in the optoelectronic device, via alignment reflective surface features provided on the optical subassembly. The optical subassembly is provided with a first alignment reflective surface directing alignment signal from the source to a grating coupler at the input of the waveguide, and a second alignment reflective surface directing to the receiver the alignment signal directed from a grating coupler at the output of the waveguide after the alignment signal has been transmitted from the input to the output through the waveguide.

Abstract: A stamped metal optic includes at least a bench for holding at least one optoelectronic component and a reflector for folding an optical pathway. The stamped metal optic is formed of a piece of metal that is shaped using known metal stamping techniques. The stamped metal optic preferably has at least one fiducial mark used to ensure that the optoelectronic device is precisely aligned with the reflector.

Abstract: Laser polishing is achieved by directing laser beam perpendicular at the fiber end face in a connectorized optical fiber having a metal ferrule. The spot size of the laser beam is larger than the bare optical fiber diameter, providing a more uniform spatial distribution of the radiation energy over the fiber end face. The metal ferrule provides heat conduction to prevent excessive heat built up at the fiber tip, which would lead to undesirable surface defects and geometries. The connectorized optical fiber may be pre-shaped prior to laser polishing. Subsequent laser polishing flattens the fiber end face.

Abstract: A vision-based passive alignment approach to optically couple input/output of optical fibers in optical alignment to optoelectronic components that are supported on a substrate. An optical bench supporting an optical fiber is physically and optically coupled to an optoelectronic device mounted on a submount via an optically transparent alignment block. The transparent alignment block having a first set of optical fiducials for aligning optical fiducials defined on the optical bench with the alignment block, and a second set of optical fiducials for aligning the alignment block with optical fiducials defined on the submount.

Abstract: A portable, hand tool for scribing optical fibers in a cleaving process. The scribing tool comprises a body within which the optical fiber is supported for rotation with respect to the body, about an axis within the body. The optical fiber is constrained by supports from movements along its axis. An actuator moves a scribing bit orthogonal relative to the fiber axis. The actuator may be a piezoelectric actuator, such as in a tube that bends under applied voltage. In one embodiment the scribing tool has a single scribing bit. In another embodiment, the scribing tool has multiple (N) scribing bits that can be applied against the optical fiber simultaneously.

Abstract: A hermetic optical subassembly includes an optical bench having a mirror directing optical signals to/from an optical waveguide, a carrier supporting a photonic device, and an intermediate optical bench having a mirror directing optical signals between the photonic device and the optical bench. The optical bench and the intermediate optical bench optically aligns the photonic device to the waveguide along a desired optical path. In one embodiment, the photonic device is an edge emitting laser (EML). The mirror of the optical bench may be passively aligned with the mirror of the intermediate optical bench. The assembled components are hermetically sealed. The body of the optical benches are preferably formed by stamping a malleable metal material to form precise geometries and surface features. In a further aspect, the hermetic optical subassembly integrates a multiplexer/demultiplexer, for directing optical signals between a single optical fiber and a plurality of photonic devices.

Abstract: A Mux/Demux subassembly includes a stamped optical bench, which includes an array of stamped reflective surfaces for redirecting optical signals. Alignment features and components of the Mux/Demux subassembly are integrally formed on a stamped optical bench, defining a desired optical path with optical alignment at tight tolerances. The optical bench is formed by stamping a malleable stock material (e.g., a metal stock), to form precise geometries and features of the optical bench.

Abstract: A compact bidirectional optical transceiver module is provided that has a bidirectional optical subassembly (BOSA) that includes a stamped metal optic that folds the optical pathway, alignment features that enable the optoelectronic components of the electrical subassembly (ESA) to be precisely aligned with the BOSA in all dimensions, and features that reduce the capacitance of the driver circuitry to improve signal integrity and widen the eye opening.

Abstract: The present invention provides a spring bias that is particularly suited for use to preload a low profile ferrule of an optical connector. In accordance with the present invention, an axial preload is applied to a connector ferrule by a spring structure provided external of the connector. In one embodiment, spring structure is provided outside a plurality of optical fiber connectors, which provides axial preload of multiple ferrules. Each ferrule could be of the type that supports a plurality of optical fibers of a fiber cable. In one embodiment, the spring bias is effected by a planar flexure external of the connector. The ferrule is coupled to the planar flexure with its longitudinal axis through the center of the planar flexure.

Abstract: A composite structure includes a base and an auxiliary portion of dissimilar materials. The auxiliary portion is shaped by stamping. As the auxiliary portion is stamped, it interlocks with the base, and at the same time forming a desired structured feature on the auxiliary portion, such as a structured reflective surface, an alignment feature, etc. With this approach, relatively less critical structured features can be shaped on the bulk of the base with less effort to maintain a relatively larger tolerance, while the relatively more critical structured features on the auxiliary portion are more precisely shaped with further considerations to define dimensions, geometries and/or finishes at relatively smaller tolerances. The auxiliary portion may include a composite structure of two dissimilar materials associated with different properties for stamping different structured features.

Abstract: A ferrule assembly for an optical fiber connector has a first ferrule component having a structured surface defining features for aligning a section of an optical fiber, and a second ferrule component that is coupled to the first ferrule component by a web, wherein the web is flexible to allow folding the web to fold the second ferrule component over the groove in the first ferrule component. The optical alignment features includes one or more open grooves for receiving a bare section of an optical fiber. The section of the optical fiber is retained in the groove between the two ferrule components.

Abstract: A ferrule for a high density optical fiber connector, supporting a first set of optical fibers of a first fiber cable and a second set of optical fibers of a second fiber cable. The ferrule supports the first and second sets of optical fibers in at least one plane. In one embodiment, the first set of optical fibers are supported in a first row of open grooves, and the second set of optical fibers are supported in a second row of open grooves. The optical fibers in the first row are staggered with respect to the optical fibers of the second row. The ferrule comprises two halves, each having an open structure that has a row of open grooves precisely formed thereon in a plane. In another embodiment, the ferrule supports the first and second sets of optical fibers in a single row, in an alternating interleaving manner.

Abstract: A compliant structure clamps the alignment pins to accurately and precisely locate the alignment pins. The compliant structure supports the alignment pins with no clearance. The compliant structure is defined by at least a flexure in the form of a cantilevered structure extending at a side of the ferrule. The cantilevered structure, with or without a complementary support structure, defines a space in which an alignment pin can be supported. The flexure may be defined by one or more slots provided on the body of the ferrule to facilitate bending of the extended cantilevered structure. In another embodiment, the ferrule comprises a ferrule insert having grooves for supporting optical fibers, and a ferrule frame that supports the ferrule insert and alignment pins. The compliant structure is provided on the frame. In a further embodiment, the ferrule insert is provided with optical fiber grooves at its perimeter.