Abstract: A high density optical fiber array assembly and assembly method includes a housing securing a front array mask etched with extreme precision to define openings arranged in a predetermined pattern. A series of guide plates form a series of fiber guide channels that align with the mask openings, which plates are stacked within the housing so that the bottom of one acts as a cover for the channels of another. Fibers can be tool inserted along the channels as one group, such as a row of fibers, or manually inserted and advanced sequentially. Alternately, the mask and guide plate stack are mounted to and within a mounting block and the mounting block assembly inserted into the assembly housing substantially all remaining voids in the housing are filled with bonding material.

Abstract: A system of making high density optical fiber arrays that includes securing the optical fiber ends in the housing front mask openings, then lapping the fiber ends and front mask forward surface to angle the fiber end front surfaces so that reflected wave energy does not interfere with optical signal data when transmitted during use. The opening pattern is preferably 2×2 to 128×128 or higher. Several alternate lap tool designs are disclosed including translational and rotating laps formed from solid bodies or a series of stacked plates. Standard slurry grinding and polishing compounds can be applied as desired. If a layer of epoxy originally covers the mask front face, it is removed by the lap tool as the fiber ends are lapped.

Abstract: A high density optical fiber array assembly and assembly method includes a housing securing a front array mask etched with extreme precision to define openings arranged in a predetermined pattern. A series of guide plates form a series of fiber guide channels that align with the mask openings, which plates are stacked within the housing so that the bottom of one acts as a cover for the channels of another. Fibers can be tool inserted along the channels as one group, such as a row of fibers, or manually inserted and advanced sequentially. Alternately, the mask and guide plate stack are mounted to and within a mounting block and the mounting block assembly inserted into the assembly housing substantially all remaining voids in the housing are filled with bonding material.

Abstract: A high density optical fiber array assembly and assembly method includes a housing securing a front array mask etched with extreme precision to define openings arranged in a predetermined pattern. A series of guide plates form a series of fiber guide channels that align with the mask openings, which plates are stacked within the housing so that the bottom of one acts as a cover for the channels of another. Fibers can be tool inserted along the channels as one group, such as a row of fibers, or manually inserted and advanced sequentially. Alternately, the mask and guide plate stack are mounted to and within a mounting block and the mounting block assembly inserted into the assembly housing substantially all remaining voids in the housing are filled with bonding material.

Abstract: A system of making high density optical fiber arrays that includes securing the optical fiber ends in the housing front mask openings, then lapping the fiber ends and front mask forward surface to angle the fiber end front surfaces so that reflected wave energy does not interfere with optical signal data when transmitted during use. The opening pattern is preferably 2×2 to 128×128 or higher. Several alternate lap tool designs are disclosed including translational and rotating laps formed from solid bodies or a series of stacked plates. Standard slurry grinding and polishing compounds can be applied as desired. If a layer of epoxy originally covers the mask front face, it is removed by the lap tool as the fiber ends are lapped.

Abstract: An optical fiber array connector in which the tolerance of the diameter of the mask openings are not factors in the overall positioning of the plurality of fibers. The array includes a mask element with rear and forward surfaces and a plurality of openings that communicate through these surfaces. A plurality of optical fibers include fiber ends having substantially truncated conical side surfaces that extend through the openings and engage the portions of the mask openings nearest the mask rear surface. A method includes preparing the fibers to form a conical surface at their distal ends, preparing the openings in the primary mask each with a diameter less than the diameter of the fiber cladding or second layer, inserting the conical fiber ends until the conical surfaces engage the mask opening walls, applying bonding material to the mask forward surface and exposed tips, grinding and polishing the exposed tips and bonding material surface to truncate the cones and expose the fiber core diameters.