US 2025/0147240 A1 · PRECISION TRANSFERRED FIBER ARRAY UNIT

Abstract

A fiber array unit, and a method and apparatus for fabricating the fiber array unit. The fiber array unit includes optical fibers that define a two-dimensional array of fiber end faces, and are encapsulated by a matrix that holds the optical fibers in place. The fiber array unit is fabricated by seating optical fibers in grooves of an arcuate surface, and applying an amount of uncured matrix thereto. A substrate is moved into contact with the matrix and the matrix cured to bond the optical fibers to each other and the substrate. The substrate is moved away from the arcuate surface to release the bonded optical fibers. The process can be repeated to fabricate a fiber array unit having multiple rows of optical fibers.

Claims20

Dependent claims

A fiber array unit, comprising:

a unit end face;
a plurality of optical fibers each including a fiber end face having an end face diameter, the optical fibers being configured so that the fiber end faces define a two-dimensional array of fiber end faces in the unit end face having an x-pitch of between 1.10 times the end face diameter and 10 times the end face diameter, and a y-pitch of between 1.10 times the end face diameter and 10 times the end face diameter;
and
a matrix encapsulating at least a portion of each of the plurality of optical fibers and holding the fiber end faces in place in the unit end face.

1 more element

A method of fabricating a fiber array unit, comprising:

seating each of a plurality of first optical fibers in a respective groove of an arcuate surface having a plurality of grooves;
applying a first amount of uncured matrix sufficient to cover at least a portion of each of the plurality of first optical fibers seated in the grooves of the arcuate surface;
moving a substrate having a fiber-side surface to a first bonding distance from the arcuate surface that brings the fiber-side surface into contact with the first amount of uncured matrix;
curing the first amount of uncured matrix so that the first optical fibers are bonded to the substrate by a first amount of cured matrix;
and
moving the substrate to a separation distance from the arcuate surface so that the plurality of first optical fibers bonded to the substrate are released from the arcuate surface.

3 more elements

An apparatus for fabricating a fiber array unit, comprising:

an arcuate surface including a plurality of grooves configured to receive a plurality of first optical fibers;
a holder configured to receive a substrate having a fiber-side surface;
and
a linear stage configured to selectively move the holder towards and away from the arcuate surface.

1 more element

Dependencies are inferred from the claim text.

Precision transferred fiber array unit

Life of this patent

Precision transferred fiber array unit

Life of this patent

Abstract

Claims20