Optical fiber connector with enhanced bonding

A connector for supporting therebetween an array of optical devices that carry optical signals, said 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 being substantially planar and having a substantially irregular surface thereon;
• the grooves of the first and second support members adapted to contain therebetween an array of optical fibers;
• and
• the irregular surfaces of the side landing sections of the first and second support members juxtaposed to substantially overlap each other when the first and second support members are placed in mating relationship around the array of optical fibers, wherein each support member is made by:
• making an array of V-grooves and side landings in monocrystalline material by photolithographic masking and etching, wherein the side landings are provided with a substantially irregular surface by:
• (a) providing a mask layer having a window opening located substantially over each side landing so as to leave only the side landings exposed;
• and
• (b) roughening the exposed side landing surfaces to obtain an irregular surface thereon;
• depositing metal on the array of V-grooves and side landings;
• removing the monocrystalline material;
• and
• using the deposited metal as a mold portion for making the support member by molding.

A connector for supporting therebetween a two-dimensional array of optical fibers, comprising:

• first and second outer 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 being substantially planar and having a substantially irregular surface thereon, wherein the support members are substantially entirely of plastic and are made by plastic molding;
• an inner support member having on each of a first and second opposing surfaces thereof a parallel array of grooves and at least one side landing section, the side landing sections being substantially planar and having a substantially irregular surface thereon;
• the grooves of the first outer support member and the first surface of the inner support member adapted to contain therebetween a first array of optical fibers, and the grooves of the second outer support member and the second surface of the inner support member adapted to contain therebetween a second array of optical fibers;
• the irregular surfaces of the side landing sections of the first and second outer support members juxtaposed to substantially overlap mating irregular surfaces of the inner support member when the first and second outer support members are placed in mating relationship around the inner support member and the first and second arrays of optical fibers.

A connector for supporting therebetween a two-dimensional array of optical fibers, comprising:

• first and second outer 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 being substantially planar and having a substantially irregular surface thereon;
• an inner support member having on each of a first and second opposing surfaces thereof a parallel array of grooves and at least one side landing section, the side landing sections being substantially planar and having a substantially irregular surface thereon;
• the grooves of the first outer support members and the first surface of the inner support member adapted to contain therebetween a first array of optical fibers, and the grooves of the second outer support member and the second surface of the inner support member adapted to contain therebetween a second array of optical fibers;
• and
• the irregular surfaces of the side landing sections of the first and second outer support members juxtaposed to substantially overlap mating irregular surfaces of the inner support member when the first and second outer support members are places in mating relationship around the inner support member and the first and second arrays of optical fibers, wherein each support member is made by:
• making an array of V-grooves and side landings in monocrystalline material by photolithographic masking and etching, wherein the side landings are provided with a substantially irregular surface by:
• (a) providing a mask layer having a window opening located substantially over each side landing so as to leave only the side landings exposed;
• and
• (b) roughening the exposed side landing surfaces to obtain an irregular surface thereon;
• depositing metal on the array of V-grooves and side landings;
• removing the monocrystalline material;
• and
• using the deposited metal as a mold portion for making the support member by molding.

A method for applying a connector to a parallel array of optical fibers that are adhered to first and second displaced substrate portions and which extend between the displaced substrate portions;

• comprising the steps of:
• providing first and second optical fiber support members having on opposing and mating surfaces thereof a substantially planar side landing section having a substantially irregular surface suitable for enhancing the bonding therebetween, containing the array of optical fibers between the first and second optical fiber support members on opposite sides of the array, applying fluid adhesive between the first and second support members and to the optical fibers and clamping together the first and second support members as the adhesive cures, and cutting transversely through the first and second support members and the optical fiber array;
• and
• making an array of V-grooves and side landings in monocrystalline material by photolithographic masking and etching, wherein the side landings are provided with a substantially irregular surface by:
• (a) providing a mask layer having a window opening located substantially over each side landing so as to leave only the side landings exposed;
• and
• (b) roughening the exposed side landing surfaces to obtain an irregular surface thereon;
• depositing metal on the array of V-grooves and side landings;
• removing the monocrystalline material;
• and
• using the deposited metal as a mold portion for making the support member by molding.