Method of forming fiber array unit structure

A method of forming a fiber array unit (FAU) structure, comprising:

• forming a reflective layer over a silicon lens layer, wherein the reflective layer comprises a plurality of reflectors, and the silicon lens layer comprises a plurality of silicon lenses adjacent to the plurality of reflectors;
• bonding a carrier board to a side of the silicon lens layer opposite the reflective layer;
• removing the reflective layer and the silicon lens layer over the carrier board in a fiber placement area of the carrier board;
• cutting through the reflective layer, the silicon lens layer, and the carrier board to separate a plurality of passive optical component structures;
• providing a fiber array unit (FAU) comprising a fiber holder holding a plurality of optical fibers;
• and
• attaching the FAU to the fiber placement area of the carrier board so that the optical fibers are close to the reflective layer.

A method of forming a fiber array unit (FAU) structure, comprising:

• forming a reflective layer over a glass substrate, wherein the reflective layer comprises a plurality of reflectors embedded within a dielectric layer;
• cutting through the reflective layer and the glass substrate to separate a plurality of passive optical component structures;
• positioning a fiber array unit (FAU) adjacent to the passive optical component structure;
• and
• attaching a L-shaped carrier to the passive optical component structure and the FAU so that a horizontal extension part of the L-shaped carrier covers top surfaces of the passive optical component structure and the FAU, and a vertical extension part of the L-shaped carrier covers a sidewall of the passive optical component structure.