Abstract: An apparatus for making optical fiber circuits including a mechanism that supplies optical fibers, a rotary support for supporting an adhesive-coated substrate in such a way that the substrate is in contact with the optical fiber, and a linear tracking arm that is equipped with a fiber routing and fixing head that routes and fixes the fibers into a shape on the substrate. Further included is a method for making optical fiber circuits including the steps of mounting a substrate on a rotary support and layering at least one layer of optical fibers from an optical fiber supply mechanism on the substrate in a shape such as a spiral by using the rotary range of motion of the substrate support and a linear range of motion of a tracking arm.

Abstract: A support member for forming connector ferrules by stacking two or more support members together has first and second longitudinally extending truncated V-grooves extending from the face of the support member. The rear portion has at least one stop member extending transversally from the wall of the groove and defining a restricted passageway in the V-groove. An alignment pin having a cylindrical shape has a reduced diameter groove near the rear portion thereof which has a diameter slightly less than the transverse dimensions of the restricted passageway and forming front and rear shoulders, spaced a distance slightly greater than the length of the stop members. The rear portion of the pin has a pair of diametrically opposed flats whose transverse spacing approximates the diameter of the reduced diameter groove.

Abstract: A support member for forming connector ferrules by stacking two or more support members together has first and second longitudinally extending truncated V-grooves extending from the face of the support member. The rear portion has at least one stop member extending transversally from the wall of the groove and defining a restricted passageway in the V-groove. An alignment pin having a cylindrical shape has a reduced diameter groove near the rear portion thereof which has a diameter slightly less than the transverse dimensions of the restricted passageway and forming front and rear shoulders, spaced a distance slightly greater than the length of the stop members. The rear portion of the pin has a pair of diametrically opposed flats whose transverse spacing approximates the diameter of the reduced diameter groove.

Abstract: Embodiments of the invention include an optical uniform spacing assembly for aligning a multipitch plurality of optical fibers into a uniform pitch linear array of optical fibers. The assembly includes an organizer body having a slot formed therein that extends longitudinally along the body. A portion of the slot has a width dimensioned to allow only one optical fiber at a time therethrough simultaneously and a depth dimensioned to align a multipitch plurality of optical fibers into a uniform pitch linear array of optical fibers. The assembly provides sufficient alignment for transitioning from, e.g., an optical fan-out arrangement such as a plurality of individual optical fibers to, e.g., an optical fan-in arrangement such as a ribbon cable arrangement. The assembly provides a compact, easily assembled apparatus and method for overcoming size mismatch and other conventional problems associated with transitioning between differing arrangements.

Abstract: A V-groove adapter for interconnecting optical conductors includes V-grooves that are precisely aligned with respect to one another to provide a desired alignment of the respective cores of the optical conductors received within the respective V-grooves. By controlling the widths of the respective V-grooves and the axial alignment of the V-grooves with respect to one another, the cores of the optical conductors received within the respective V-grooves can be coaxially aligned or offset by predetermined distance with repeatable precision on the order of 1 &mgr;m. The V-grooves are initially fabricated in a monocrystalline material. A metal layer is formed over the V-grooves in order to form an inverse replica of the V-grooves which is used as an insert in an injection mold so that the V-groove adapters can be mass produced using injection molding techniques.

Abstract: A stackable multi-fiber ferrule of the present invention enables relatively tighter stacking between fiber arrays, resulting in increased interconnection density. The present invention achieves tighter stacking by incorporating an inner support member having alignment pin grooves on only one side, thereby permitting the thickness of the support member to be reduced. Thus, the thickness of the inner support member may be thinner than that of conventional support members because the inner support member of the present invention does not have to accommodate opposing alignment pin grooves on both sides thereof. Thus, a multi-fiber stackable ferrule in accordance with the present invention will have alignment pin holes on alternating rows of fibers, that is, on every other interface between adjacent support members. Accordingly, a stackable multi-fiber ferrule in accordance with the present invention is capable of improved interconnection density.

Abstract: The present invention is an optical harness and method for an optical cross-connect. The optical harness is defined primarily by a first portion and a second portion. The first portion of the optical harness comprises a number M of fiber optic row cables where each fiber optic row cable comprises an array of a number N of fiber optics arranged on a first plane. The first plane on which each fiber optic row cable is disposed is substantially parallel to each of the other first planes on which a fiber optic row cable is disposed. The second portion of the optical harness comprises a number N of fiber optic column cables where each fiber optic column cable comprises an array of a number M of fiber optics arranged on a second plane. Each fiber optic column cable is disposed on a second plane being substantially parallel to each of the other second planes on which each other fiber optic column cable is disposed.

Abstract: An alignment sleeve in accordance with the present invention interconnects optical ferrules of dissimilar size and axially aligns the ferrules with precision in a mating relationship so as to reduce loss in the optical signal passed from one ferrule to the other. A plurality of lands on the inner wall of the alignment sleeve contact and hold the respective ferrules in a predetermined axial relationship with respect to one another. The alignment sleeve comprises a compliant material which conforms to slight variances in the diameters of the ferrules received by the alignment sleeve. The alignment sleeve advantageously provides for the interconnection of ferrules of dissimilar size with precise alignment of their respective cores, which reduces the connection loss of the two ferrules. The alignment sleeve can be mass produced using injection molding techniques. The mold utilized in the injection molding process includes a precision core pin that can be manufactured using a precision grinder or lathe.

Abstract: A small form factor, multi-fiber connector having the footprint of a LC connector for high density applications is disclosed. A multi-fiber ferrule, which may or may not be stacked, is received in the front end of the housing. A spring member is disposed within the housing for axially urging the multi-fiber ferrule outwardly to maintain the end face of the ferrule flush with the device to which it is coupled. The housing includes an end cap which snaps into the housing body and holds the spring member. Thus, a multi-fiber stackable connector in accordance with the present invention is relatively simple in construction and assembly, inexpensive, and user friendly.

Abstract: Methods and tools disclosed herein enable the efficient assembly of a stackable multi-fiber ferrule. The present invention facilitates precisely aligned support members within the stack. In addition, the present invention provides for the consistently high precision repetition of the assembly of stackable multi-fiber ferrules. Thus, stackable multi-fiber ferrules assembled in accordance with the present invention are capable of consistently establishing highly efficient optical connections.

Abstract: An alignment adapter for use with a multi-fiber, optical connector that is in the form of a substantially planar slab having a central opening for receiving a connector therethrough. The slab includes a pair of alignment apertures on opposing sides of the central opening that are positioned in a defined spatial relationship with the fibers held in the multi-fiber connector. According to an aspect of the invention, the alignment adapter includes a pair of alignment rods held in the alignment apertures that are used to convert an optical connector into a male type connector. According to another aspect of the present invention, a connector is disclosed having a plurality of channels for holding optical fibers and a pair of alignment apertures positioned adjacent to the fiber holding channels in a defined spatial relationship.

Abstract: A method for making an optical connector support member. The method can be broadly summarized by the following steps: One or more features are partially etched in a monocrystalline substrate to form a template. The features are etched in the substrate to a depth necessary to form the functional portions of the features. An inverse replica is created and then separated from the template. Additional material is bonded to the inverse replica in the regions that correspond to the features that were partially etched in the monocrystalline substrate. The inverse replica with the additional material bonded thereto is then used as a pattern for making a support member. A multi-fiber support member made using the inverse replica described in the foregoing will have one or more features formed therein that correspond to the features etched in the monocrystalline substrate, but are deeper because of the additional material that was bonded to the inverse replica.

Abstract: An improved optical fiber connector design and associated manufacturing method which provides increased manufacturing throughput by molding connector bodies as a unitary molded part as joined back-to-back pairs of connector bodies.

Abstract: An optoelectronic module is disclosed in which an optoelectronic device is precisely aligned with an optical fiber. The optoelectronic module comprises a first member, a second member for supporting an end of the optical fiber in a fixed position relative the first member along an axis, and a third member for mounting at least one optoelectronic device. A plurality of positioning members are adjustably positioned on the first member for supporting the third member to maintain aligned relation of the optoelectronic device with the axis.

Abstract: An optical device such as an optical fiber waveguide having at least one light transceiving end suitable for transmitting or receiving light, the optical device comprising a core suitable for allowing transmission therethrough of light, a cladding layer surrounding the core and having an index of refraction less than that of the core, and an embedded lens integrally located at the light transceiving end. The embedded lens is preferably a gradient refractive index (GRIN) lens having a refractive index that varies along a radial axis of the light transceiving end of the device and along a longitudinal axis of the light transceiving end of the device. The embedded GRIN lens is comprised of a plurality of dopant regions; the dopant regions comprise regions extending a predetermined distance along the longitudinal axis and having a predetermined diameter.

Abstract: An improved fiber optic connector for supporting therebetween an array of optical fibers, the connector comprising first and second support members, each having on a first surface thereof a parallel array of grooves and at least one side landing section. The side landing section of the support member is substantially planar and has a substantially irregular surface thereon for enhancement of bonding between the support members. The grooves of the first and second support members are adapted to contain therebetween the array of optical fibers. The irregular surfaces of the side landing sections of the first and second support members are juxtaposed to substantially overlap each other when the first and second support members are placed in mating relationship around the array of optical fibers. The irregular surfaces of the side landings are joined together around the array of optical fibers with an adhesive epoxy.

Abstract: An optical fiber support member is made by forming on a monocrystalline silicon substrate member (26) a first mask layer (27) of, e.g., silicon dioxide. The first mask layer is masked and etched to a first depth to define a pattern of first (29) and second (30) features, the first features defining the locations of optical fiber support grooves (15), and the second features defining the locations of support member reference surfaces (17, 19). Next, only the second features are etched to a second depth deeper than the first depth. Finally, the first and second features are simultaneously etched into the substrate such that the second features are etched to a greater depth than the first features. By defining the first and second features simultaneously in a single mask and etch step, one can assure the final precise alignment of etched V-grooves to etched reference surfaces.

Abstract: The specification describes a fiber lightguide connector for interconnecting large arrays of lightwave fibers. Linear arrays of lightwave fibers, for example those in so-called ribbon cables, are effectively interconnected using known v-groove connector assemblies. According to the invention two or more such v-groove connector assemblies are stacked to increase the fiber capacity of a connector assembly. Attempts to stack known v-groove connector plates have encountered problems with aligning the v-groove arrays on opposite sides of the internal or intermediate plate of the stack. An alignment technique is described for assuring precise alignment between linear arrays of v-grooves on opposite sides of the interior plates of stacked linear array connectors.

Abstract: The specification describes a connector assembly for interconnecting lightwave waveguide arrays to lightwave fiber arrays. It uses passive alignment means in the form of grooves and pins. The grooves and pins are formed in a precise dimensional relationship with the light path in the two halves of the assembly so that when the pins are inserted into the v-grooves the lightguides align precisely.

Abstract: Optical fiber support members (30 and 31) are formed by making an array of V-grooves (25) in a monocrystalline material (26), depositing metal (27) on the array, and removing the metal member to provide an insert. The insert is used to form the support members by injection molding.