Abstract: A process and tool for reshaping and resizing grooves that were pre-formed in a pair of ferrules halves of an optical fiber ferrule. The pre-formed grooves are further subject to a separate, subsequent reshaping and resizing step using the tool and a gauge that may be a bare section of optical fiber or a pin. The ferrule halves are aligned, and using the pre-formed grooves as guides for the gauge optical fiber or gauge pin, the ferrule halves are compressed together with the gauge optical fiber or gauge pin therebetween, thereby reshaping and resizing the respective grooves on the ferrule halves. After reshaping and resizing, the resultant groove that is finally formed on each ferrule halve would be precisely shaped, sized and located with respect to the external alignment surface of each ferrule halve. The ferrule halves may be used to terminate an optical fiber cable.

Abstract: A coupling device for physically and optically coupling an input/output end of an optical fiber for routing optical signals, to and from optical receiver and/or transmitter. The coupling device includes a structured reflective surface that functions as an optical element that directs light to/from the input/output ends of the optical fiber by reflection, and an optical fiber retention groove structure that positively receives the optical fiber in a manner with the end of the optical fiber at a defined distance to and aligned with the structured reflective surface. The open structure of the structured reflective surface and fiber retention structure lends itself to mass production processes such as precision stamping. The coupling device can be attached to an optical transmitter and/or receiver, with the structured reflective surface aligned to the light source in the transmitter or to the detector in the receiver, and adapted in an active optical cable.

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 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 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: To couple light between an optical fiber and a grating coupler of a photonic integrated circuits, a mirror is provided to turn light to/from the optical fiber to allow the axis of the optical fiber to be oriented at small angles or parallel to the surface of the PIC, and lowered close to the surface of the PIC. The mirror is further configured to reshape light from a flat polished optical fiber to produce a mode field resembling the mode field of an angled polished optical fiber, to match the design angle of existing grating couplers that are designed to work with angled polished optical fibers. The mirror and optical fiber alignment structure in the optical connector are integrally/simultaneous formed by precision stamping.

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: 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 hermetic optical fiber alignment assembly includes a ferrule portion having a plurality of grooves receiving the end sections of optical fibers, wherein the grooves define the location and orientation of the end sections with respect to the ferrule portion. The assembly includes an integrated optical element for coupling the input/output of an optical fiber to the opto-electronic devices in the opto-electronic module. The optical element can be in the form of a structured reflective surface. The end of the optical fiber is at a defined distance to and aligned with the structured reflective surface. The structured reflective surfaces and the fiber alignment grooves can be formed by stamping.

Abstract: A coupling device for physically and optically coupling an input/output end of an optical fiber for routing optical signals, to and from optical receiver and/or transmitter. The coupling device includes a structured reflective surface that functions as an optical element that directs light to/from the input/output ends of the optical fiber by reflection, and an optical fiber retention groove structure that positively receives the optical fiber in a manner with the end of the optical fiber at a defined distance to and aligned with the structured reflective surface. The open structure of the structured reflective surface and fiber retention structure lends itself to mass production processes such as precision stamping. The coupling device can be attached to an optical transmitter and/or receiver, with the structured reflective surface aligned to the light source in the transmitter or to the detector in the receiver, and adapted in an active optical cable.

Abstract: A hermetic optical fiber alignment assembly, including a first ferrule portion having a first surface provided with a plurality of grooves receiving the end sections of optical fibers, wherein the grooves define the location and orientation of the end sections with respect to the first ferrule portion, and a second ferrule portion having a second surface facing the first surface of the first ferrule, wherein the first ferrule portion is attached to the second ferrule portion with the first surface against the second surface, wherein a cavity is defined between the first ferrule portion and the second ferrule portion, wherein the cavity is wider than the grooves, and wherein a suspended section of each optical fiber is suspended in the cavity, and wherein the cavity is sealed with a sealant. The sealant extends around the suspended sections of the optical fibers within the cavity.

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.

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.

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 hermetic optical fiber alignment assembly, including a first ferrule portion having a first surface provided with a plurality of grooves receiving the end sections of optical fibers, wherein the grooves define the location and orientation of the end sections with respect to the first ferrule portion, and a second ferrule portion having a second surface facing the first surface of the first ferrule, wherein the first ferrule portion is attached to the second ferrule portion with the first surface against the second surface, wherein a cavity is defined between the first ferrule portion and the second ferrule portion, wherein the cavity is wider than the grooves, and wherein a suspended section of each optical fiber is suspended in the cavity, and wherein the cavity is sealed with a sealant. The sealant extends around the suspended sections of the optical fibers within the cavity.

Abstract: An optical coupling device for routing optical signals for use in an optical communications module, in which defined on a base are a structured surface having a surface profile that reshapes and/or reflect an incident light, and an alignment structure defined on the base, configured with a surface feature to facilitate positioning an optical component on the base in optical alignment with the structured surface to allow light to be transmitted along a defined path between the structured surface and the optical component. The structured surface and the alignment structure are integrally defined on the base by stamping a malleable material of the base. The alignment structure facilitates passive alignment of the optical component on the base in optical alignment with the structured surface to allow light to be transmitted along a defined path between the structured surface and the optical component. The structured surface has a reflective surface profile, which reflects and/or reshape incident light.

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 ferrule for an optical fiber connector having open fiber clamping grooves. The ferrule has a body having a plurality of open grooves for clamping the terminating end sections of optical fibers. At least a section of the longitudinal opening of the groove is provided with opposing lips to provide a clamping effect. The width of the longitudinal opening defined between the lips along at least a section of the grooves is narrower than the diameter of the optical fibers to create a tight fit. The grooves and the width of the longitudinal groove openings are shaped and sized to retain the fibers without any clearance to allow for movement of the fiber relative to the groove. Similar grooves may be provided in the ferrule body for alignment guide pins. The grooves are precision formed by high throughput processes, such as stamping and extrusion.