Mechanical couplers for fiber array units and methods of manufacturing the same

A fiber array unit, comprising:

• a substrate comprising:
• fiber couplers formed in a surface of the substrate, wherein the fiber couplers extend substantially parallel to each other on the surface of the substrate, and wherein each of the fiber couplers is configured for receiving an optical fiber;
• and
• substrate mechanical couplers formed in the surface of the substrate, wherein the substrate mechanical couplers extend substantially parallel to the fiber couplers on the surface of the substrate, and wherein each substrate mechanical coupler is configured to receive and mechanically couple with a corresponding receptacle mechanical coupler of a receptacle such that an optical element of the receptacle optically couples an optical device and optical fibers positioned in the fiber couplers;
• and
• wherein the fiber array unit is configured to detachably connect to the receptacle.

A method of manufacturing an optical connector, the method comprising:

• forming fiber couplers in a surface of a substrate of a fiber array unit such that the fiber couplers extend substantially parallel to each other on the surface of the substrate and such that each of the fiber couplers is configured for receiving an optical fiber;
• forming substrate mechanical couplers in the surface of the substrate such that the substrate mechanical couplers extend substantially parallel to the fiber couplers on the surface of the substrate;
• providing an optical element on a receptacle body of a receptacle;
• and
• forming receptacle mechanical couplers on the receptacle body such that each receptacle mechanical coupler is configured to mechanically couple with a corresponding substrate mechanical coupler, of the substrate mechanical couplers, and such that the optical element optically couples an optical device and optical fibers positioned in the fiber couplers when the fiber array unit is positioned in the receptacle.