# US 2024/0201453 A1 · Molded optical connectors with zero-draft mechanical alignment features > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2024/0201453 A1 - Document ID: US20240201453A1 - Status: Published application - Kind: A1 - Application number: 18/288,664 - Filed: 2022-04-22 - Published: 2024-06-20 - Earliest claimed: 2021-05-04 - Assignees: 3M Innovative Properties Company - Applicants: 3M Innovative Properties Company - Inventors: Michael A. Haase; Nicholas A. Lee - Web page: https://patentgrep.com/patent/US20240201453A1 ## CPC - G02B 6/4214: {the intermediate optical element having redirecting reflective means, e.g. mirrors, prisms for deflecting the radiation from horizontal to down- or upward direction toward a device (G02B6/4246 takes precedence)} - G02B 6/3881: {using grooves to align ferrule ends} - G02B 6/3885: {Multicore or multichannel optical connectors, i.e. one single ferrule containing more than one fibre, e.g. ribbon type (optical ribbon cable G02B6/4403, G02B6/448)} - G02B 6/423: {using guiding surfaces for the alignment} - G02B 6/4292: {the light guide being disconnectable from the opto-electronic element, e.g. mutually self aligning arrangements} - G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS ## Abstract A molded optical ferrule configured to mate with a mating component includes a top surface, a bottom surface opposite the top surface, and a plurality of side surfaces joining the top and bottom surfaces. The plurality of side surfaces includes a plurality of first side surface portions and a plurality of second side surface portions. The first side surface portions make a first angle greater than zero degrees with a thickness direction of the optical ferrule, the first angle assisting in the removal of the optical ferrule from a mold. The plurality of second side surface portions extends outwardly from the first side surface portions and makes a second angle less than the first angle with the thickness direction. When the optical ferrule mates with the mating component, at least some of the second, but not the first, side surface portions contact corresponding side surface portions of the mating component. ## Claims ### Claim 1 A molded optical ferrule configured to mate with a mating optical component and comprising: a top surface comprising an attachment area for attaching to an optical waveguide and a light redirecting member for receiving light from the optical waveguide attached to the attachment area along a first direction and redirecting the received light along a different second direction; a bottom surface opposite the top surface and comprising an exit window, the top and bottom surfaces defining a thickness direction of the molded optical ferrule therebetween, the light redirected by the light redirecting member exiting the molded optical ferrule through the exit window; and a plurality of side surfaces joining the top and bottom surfaces and comprising: a plurality of first side surface portions making a first angle greater than zero degrees with the thickness direction, the first angle assisting in a removal of the molded optical ferrule from a corresponding mold; and a plurality of second side surface portions extending outwardly from at least some of the plurality of first side surface portions and making a second angle less than the first angle with the thickness direction, such that when the molded optical ferrule mates with the mating optical component, at least some of the second, but not the first, side surface portions contact corresponding side surface portions of the mating optical component. ### Claim 2 (depends on 1) The molded optical ferrule of claim 1, wherein a maximum dimension of each second side surface portion of the plurality of second side surface portions is 200 microns. ### Claim 3 (depends on 1) The molded optical ferrule of claim 1, wherein at least 50% of a surface area of each of the plurality of second side surface portions is in contact with the corresponding side surface portions of the mating optical component. ### Claim 4 (depends on 1) The molded optical ferrule of claim 1, wherein the mating optical component is a mating optical ferrule. ### Claim 5 (depends on 1) The molded optical ferrule of claim 1, wherein the mating optical component is a mating optical cradle. ### Claim 6 (depends on 1) The molded optical ferrule of claim 1, wherein the first angle is greater than or equal to 1 degree. ### Claim 7 (depends on 1) The molded optical ferrule of claim 1, wherein the second angle is less than about an intended 1 degree. ### Claim 8 (depends on 1) The molded optical ferrule of claim 1, wherein the second angle is an intended 0 degrees. ### Claim 9 A molded optical cradle configured to mate with a mating optical ferrule and configured to align the mating optical ferrule to an optical device, the molded optical cradle comprising: a top major surface; an opposing bottom major surface, the top major surface and bottom major surface defining a thickness direction of the molded optical cradle therebetween; and a recess configured to accept the mating optical ferrule, the recess extending between the top major surface and the bottom major surface in the thickness direction and comprising a plurality of inner side surfaces; each inner side surface of the plurality of inner side surfaces comprising a plurality of first side surface portions making a first angle greater than zero degrees with the thickness direction, the first angle assisting in a removal of the molded optical cradle from a corresponding mold; and a plurality of second side surface portions extending outwardly from at least some of the plurality of first side surface portions and making a second angle less than the first angle with the thickness direction, such that when the molded optical cradle is mated with the mating optical ferrule, at least some of the second, but not the first, side surface portions contact corresponding side surface portions of the mating optical ferrule. ### Claim 10 (depends on 9) The molded optical cradle of claim 9, wherein the optical device is a photonic integrated circuit, a lens, or a grating. ### Claim 11 (depends on 9) The molded optical cradle of claim 9, wherein the first angle is greater than or equal to 1 degree. ### Claim 12 (depends on 9) The molded optical cradle of claim 9, wherein the second angle is about an intended 0 degrees. ### Claim 13 An optical assembly comprising: a molded optical ferrule comprising: a top surface comprising an attachment area for attaching to an optical waveguide and a light redirecting member for receiving light from the optical waveguide attached to the attachment area along a first direction and redirect the received light along a different second direction; a bottom surface opposite the top surface and comprising an exit window, the top and bottom surfaces defining a thickness direction of the molded optical ferrule therebetween, the light redirected by the light redirecting member exiting the molded optical ferrule through the exit window; and a plurality of side surfaces joining the top and bottom surfaces and comprising: a plurality of first side surface portions making a first angle greater than zero degrees with the thickness direction of the molded optical ferrule, the first angle assisting in a removal of the molded optical ferrule from a corresponding mold; and one or more second side surface portions extending outwardly from at least some of the plurality of first side surface portions and making a second angle less than the first angle with the thickness direction of the molded optical ferrule; and an optical cradle comprising a recess configured to accept the molded optical ferrule therein and to align the molded optical ferrule to an optical device, the recess extending between a first major surface and a second major surface of the optical cradle in a thickness direction of the optical cradle and comprising a plurality of inner side surfaces; wherein at least some of the one or more second side surface portions of the molded optical ferrule make contact with at least some of the plurality of inner side surfaces of the optical cradle when mated. ### Claim 14 (depends on 13) The optical assembly of claim 13, wherein a maximum dimension of each second side surface portion of the one or more second side surface portions is 200 microns. ### Claim 15 (depends on 13) The optical assembly of claim 13, wherein each of the one or more second side surface portions of the one or more second side surface portions make an intended angle of about 0 degrees with the thickness direction. ### Claim 16 (depends on 13) The optical assembly of claim 13, wherein the optical device is a photonic integrated circuit, a lens, or a grating. ### Claim at position 17 17-26. (canceled)