Optical fiber array with variable fiber angle alignment and method for the fabrication thereof

A fiber array comprising:

• a plurality of optical fibers;
• a first silicon substrate comprising a first plurality of fiber passageways extending therethrough from a first surface of the substrate, wherein each of the passageways of the first substrate comprises a cylindrical sidewall;
• a second silicon substrate comprising a second plurality of fiber passageways extending therethrough, wherein each of the optical fibers is disposed in a respective passageway of the first and second substrates;
• and
• a bonding agent to secure the fibers and substrates in fixed relation to one another;
• wherein the fibers are oriented at a selected, non-perpendicular angle relative to the first surface of the substrate.

A fiber array comprising:

• a plurality of optical fibers;
• a first silicon substrate comprising a first plurality of fiber passageways extending therethrough from a first surface of the substrate;
• a second silicon substrate comprising a second plurality of fiber passageways extending therethrough, wherein each of the optical fibers is disposed in a respective passageway of the first and second substrates;
• a third silicon substrate comprising a third plurality of fiber passageways extending therethrough, wherein each of the optical fibers is disposed in a respective passageway of the third substrate;
• and
• a bonding agent to secure the fibers and substrates in fixed relation to one another;
• wherein the fibers are oriented at a selected, non-perpendicular angle relative to the first surface of the substrate.

A method for fabricating a fiber optic array, comprising:

• providing a first substrate comprising a first plurality of fiber passageways extending therethrough from a first surface of the substrate;
• providing a second substrate comprising a second plurality of fiber passageways extending therethrough;
• positioning the second substrate relative to the first substrate so that each passageway of the first substrate is registered to a respective passageway of the second substrate;
• placing an optical fiber in each of the registered passageways, wherein the passageways are dimensioned to permit the optical fibers disposed therein to be positioned at a range of angles relative to the first surface of the substrate;
• moving the second substrate relative to the first substrate so as to orient the fibers at a selected non-orthogonal angle relative to the first surface of the substrate;
• and
• securing the fibers and the substrates to one another with a bonding agent,
• whereby a fiber array is provided in which the fibers are oriented at the selected, non-orthogonal angle relative to the first surface of the first substrate.