Devices and methods for side-coupling optical fibers to optoelectronic components

A method for fabricating an optical connector that side-couples to an optical component, comprising the steps of:

• etching a substrate to form a first array of tapered v-groove channels in a first portion of the substrate and to form a second array of tapered v-groove channels in a second portion of the substrate, wherein each tapered v-groove channel in the first and second arrays is inclined relative to the surface of the substrate, and wherein each tapered v-groove in the first array is axially aligned with a tapered v-groove in the second array;
• etching the tapered v-grooves of the first array to form recessed v-groove channels in the first portion of the substrate;
• etching the second portion of the substrate and the tapered v-groove channels of the second array to form a cavity in the substrate having an array of recessed v-groove channels formed in a bottom portion of the cavity;
• stripping an end portion of a fiber optic cable such that the end portion comprises a buffer polymer layer portion with optical fibers extending therefrom;
• mounting the stripped end portion of a fiber optic cable in the substrate such that the buffer polymer portion is mounted in the recessed cavity of the second portion of the substrate and the optical fibers extending from the buffer polymer portion are mounted in the recessed v-groove channels of the first portion of the substrate;
• and
• removing a portion of the optical fibers and polymer buffer layer extending beyond the surface of the substrate.