Process for fabricating a photonics package and for aligning an optical fiber with a photodetector surface during fabrication of such a package

A process for fabricating an optical fiber assembly for a photonics package comprising:

• positioning a photodetector in a housing;
• securing a cylindrical, elongated ferrule coaxially around a jacketed optical fiber;
• exposing the distal end of the fiber;
• adjustably positioning the ferrule coaxially within a cylindrical flange;
• securing the ferrule within the flange;
• inserting the distal end of the fiber into the housing through a fiber alignment window;
• initially welding the flange to the housing;
• activating a settable sealing material in a groove on the housing for hermetically sealing the flange to the housing;
• and
• adjusting the position of the flange on the housing while the sealing material sets to seal the flange to the housing and to accurately position the optical fiber with resepect to the photodetector.

A photonics package including:

• a housing including spaced front and back walls;
• an apeture in said front wall;
• a photosensitive element mounted on said back wall within the housing and in alignment with said aperture,
• a first closure for said aperture;
• a fiber alignment window in said first closure opposite said photosensitive element;
• a viewing aperture in said housing providing access to the interior of said housing during assembly of said photonics package;
• a fiber optic assembly including an optical fiber, a ferrule coaxial with and surronding said optical fiber, and a cylindrical flange receiving said ferrule, said assembly being locatd so that said fiber extends through said alignment window into said housing and with said flange abutting said front wall and covering said window, said flange being laterally adjustable with respect to said window and with respect to said photosensitive element and intially secured to said front wall via welding;
• a groove located on said front wall adjacent said alignment window, said groove containing a settable sealing material;
• and
• said flange being hermetically sealed to said front wall by said settable material and further laser welded to secure said optical fiber to allow alignment of said optical fiber while said material is setting to position said optical fiber in said fiber alignment window and to align the distal end of the fiber with said photosensitive elelment.