Abstract: Two ribbon cables are partially stripped of their covering to reveal a window of optical fibers. The bare optical fibers are slightly bent and overlapped so that they define an interior channel. A rod is passed through the interior channel to temporarily hold the bare fibers in place. The bare fibers are placed on a v-groove substrate and a cover is pressed on top of the substrate. Adhesives are applied to hold the ribbon cables and bare fibers in place. The bare fibers are cleaved to form a half-pitch optical fiber array.

Abstract: One preferred optical fiber array according to the present invention includes a lower substrate, a ribbon cable, a cover and a housing. The lower substrate has a first end and a second end opposed thereto and an upper surface extending between the first end and the second end. The upper surface defines a plurality of grooves that extend across at least a portion of the upper surface. The ribbon cable comprising a plurality of coated optical fibers. An end of the coated optical fibers are bare of the coating. At least a portion of the bare end of each of the plurality of coated fibers rests in one of the plurality of grooves and extend to the first end of the lower substrate. The cover is positioned proximate the first end of the lower substrate and over at least a portion of the bare end of each of the plurality of coated fibers. The cover is bonded to the lower substrate.

Abstract: Two ribbon cables are partially stripped of their covering to reveal a window of optical fibers. The bare optical fibers are slightly bent and overlapped so that they define an interior channel. A rod is passed through the interior channel to temporarily hold the bare fibers in place. The bare fibers are placed on a v-groove substrate and a cover is pressed on top of the substrate. Adhesives are applied to hold the ribbon cables and bare fibers in place. The bare fibers are cleaved to form a half-pitch optical fiber array.