GB2317242A

GB2317242A - Optical fibre array module and fabrication method

Info

Publication number: GB2317242A
Application number: GB9718023A
Authority: GB
Inventors: Byong-Gwon You; Tae-Hyung Rhee
Original assignee: Samsung Electronics Co Ltd
Current assignee: Samsung Electronics Co Ltd
Priority date: 1996-09-13
Filing date: 1997-08-27
Publication date: 1998-03-18
Anticipated expiration: 2017-08-27
Also published as: GB9718023D0; DE19740260A1; FR2753542B1; KR19980021125A; FR2753542A1; GB2317242B; IN192562B; KR100191211B1; RU2141122C1; CN1089445C; CN1179547A; JPH10104462A

Abstract

An optical fibre array module is described. A flat substrate 10 is provided with a plurality of apertures, namely channels formed in a surface of the substrate, at specified intervals. A corresponding plurality of optical fibres 16 are aligned and arrayed in the apertures. Then an epoxy moulding 14 is applied extending over that surface of the substrate 10 to fix the optical fibres 16 in the apertures.

Description

1 2317242 OPTICAL FIBRE ARRAY MODULE AND FABRICATION METHOD

Background of the Invention

The present invention relates to an optical f ibre array module for facilitating the junction of light waveguide elements and optical fibres.

In general, when fibres are joined to optical waveguide 10 components, it is very important that the fibres be aligned precisely. To deal with that requirement, the spacing and alignment of optical waveguide components are achieved with considerable precision by photolithographic processes, but it is very difficult to align and array precisely the single or multiple optical fibres when joining the optical fibres to optical waveguide components.

In the conventional method, usually silicon wafers and metal plates are provided with specified grooves in which single or multiple optical fibres are accommodated, aligned and arrayed within the grooves.

Accordingly, the conventional process of forming grooves on the substrates must be carried out very precisely, as must the polishing of the cross sections of the fibre ends after mounting within the grooves of the substrates. The polishing process must be carefully and precisely carried out because of the very small cross- sections of the fibre ends. Further, since the size of the junction between the optical waveguide components and the optical fibres is small, the strength of the spliced joints is low, resulting in deterioration of the performance of the optical waveguides.

Summary of the Invention

An objective of the present invention is to provide an optical fibre array module in which the alignment and arraying processes are simplified and the finishing of the 2 fibre ends is facilitated.

It is another objective of the present invention to provide an optical fibre array module capable of improved tensile 5 strength at the junction between the optical fibres and the waveguide components.

It is a further objective of the present invention to provide an optical fibre array module capable of improving the performance of the entire optical waveguide.

Accordingly, the present invention provides an optical fibre array module comprising: a flat substrate provided with a plurality of apertures at specified intervals for aligning and arraying a corresponding plurality of optical fibres; and a moulding for fixing the optical fibres in the apertures.

Preferably, the said apertures are channels formed in a surface of the substrate and the moulding is an epoxy moulding extending over that surface of the substrate. The channels may be cylindrical or square in cross-section. The substrate may be a flat metal plate. 25 Preferably, the plurality of apertures are formed obliquely to reduce return losses incurred when joining the optical fibres to optical waveguide components. The apertures may be formed at an angle of 1-20 degrees within the substrate. 30 The present invention also provides a method of fabricating an optical fibre array module comprising: forming a plurality of apertures at specified intervals on a flat substrate; 35 aligning and arraying a corresponding plurality of optical fibres in the apertures; and applying a moulding to fix the optical fibres in the apertures.

3 The optical f ibres may be aligned by means of an aligning jig after being inserted into the respective apertures.

The method may further comprise polishing the ends of the optical fibres.

The apertures may be formed by machining or by a photolithographic process and may be cylindrical or square in cross-section.

Brief Description of the Drawings

The present invention will now be described by way of example with reference to the accompanying drawings in which:

Fig. 1 is a schematic perspective view of an optical fibre array module; Fig. 2 is a top plan view of the optical f ibre array module; Fig. 3 is a cross-sectional view showing optical fibres aligned in the respective apertures formed within the substrate; Fig. 4a is a side view of the substrate showing the apertures formed vertically; and Fig. 4b is a side view of the substrate showing the apertures formed obliquely.

Detailed Description of the Preferred Embodiment

Referring to Figs. 1-3, the above optical fibre array module consists largely of a flat metal substrate 10 and an epoxy moulding 14. The substrate 10 is provided with a plurality of apertures 12 formed inside of and perpendicular to the substrate 10 in the shape of cylindrical or square holes at specified intervals. The apertures are designed to align and array optical fibres 16, allowing single or multiple optical fibres 16 and optical waveguide components to be joined to each other.

4 The apertures 12 are formed obliquely in the substrate 10 at a specified angle (8) to decrease return losses which occur when the optical fibres 16 are joined to the optical waveguide components. That is, the apertures 12 are 5 inclined at 1-20 degrees in the substrate 10.

The moulding 14 is formed by epoxying the optical fibres 16 into the respective apertures 12 to completely fix them there after inserting the single or multiple optical fibres 16 into the substrate apertures 12.

The method of fabrication of the optical fibre array module as above is as follows. Firstly, the flat metal substrate 10 is positioned vertically as shown in Fig. 4a, and a plurality of cylindrical or square sleeve-like apertures 12 are formed within the substrate 10 at specified intervals by means of a machining or photolithographic process.

To decrease the return loss incurred when the optical fibres and the optical waveguides are joined to each other, at first the substrate 10 is positioned obliquely at a specified angle (8) as shown in Fig. 4b and then the apertures are formed.

Thereafter, the optical fibres 16 are each inserted into their respective apertures 12 and aligned and arrayed by means of an aligning jig. The entire surface of the resulting structure is moulded with epoxy resin to completely fix the optical fibres 16. The epoxy resin may be hardened by heating or exposure to UV light. Lastly, the optical fibre ends projecting out of the apertures 12 are ground and polished to maintain optimum optical illuminance. Thus, a precision optical fibre array module is fabricated.

As described above, the optical fibre array module of the present invention has the advantages that the size of the junction between the optical fibres and waveguide elements is maximized so that the tensile strength at the junction area is improved and accordingly the reliability of the optical waveguide component package is increased. The fabrication of the optical fibre array module is simplified by forming apertures through a metal substrate and inserting optical fibres into the apertures to align and array them and the simplified fabrication process reduces the production cost of the optical fibre array module. The return loss which occurs when the optical fibres 16 aligned within the substrate 10 are joined to the optical waveguide components is reduced by inclining the apertures 12 at a specified angle (0) between 1-20 degrees in the substrate 10.

6

Claims

1. An optical fibre array module comprising: a flat substrate provided with a plurality of apertures at specified intervals for aligning and arraying a corresponding plurality of optical fibres; and a moulding for fixing the optical fibres in the apertures.

2. An optical fibre array module according to claim 1 in which the said apertures are channels formed in a surface of the substrate and the moulding is an epoxy moulding extending over that surface of the substrate.

3. An optical fibre array module according to claim 2 in which the channels are cylindrical or square in crosssection.

4. An optical fibre array module according to any preceding claim in which the substrate is a flat metal plate.

5. An optical fibre array module according to any preceding claim in which the plurality of apertures are formed obliquely to reduce return losses incurred when joining the optical fibres to optical waveguide components.

6. An optical fibre array module according to any claim 5 in which the apertures are formed at an angle of 1-20 degrees within the substrate.

7. An optical fibre array module substantially as described herein with reference to and/or as illustrated in the accompanying drawings.

8. A method of fabricating an optical fibre array module comprising: forming a plurality of apertures at specified 7 intervals on a flat substrate; aligning and arraying a corresponding plurality of optical fibres in the apertures; and applying a moulding to fix the optical f ibres in the 5 apertures.

9. A method according to claim 8 in which the optical fibres are aligned by means of an aligning jig after being inserted into the respective apertures.

10. A method according to claim 8 or claim 9 in which the said apertures are channels formed in a surface of the substrate and the moulding is an epoxy moulding applied over that surface of the substrate.

11. A method according to any one of claims 8-10 further comprising polishing the ends of the optical fibres.

12. A method according to any one of claims 8-11 in which the apertures are formed by machining or by a photolithographic process.

13. A method according to any one of claims 8-12 in which the apertures are cylindrical or square in cross-section.

14. A method according to any one of claims 8-1 in which the apertures are formed obliquely to reduce return losses incurred when joining the optical fibres to optical waveguide components.

15. A method of fabricating an optical fibre array module substantially as described herein with reference to and/or as illustrated in the accompanying drawings.