US20130322818A1 - Coupling device having a structured reflective surface for coupling input/output of an optical fiber - Google Patents

Coupling device having a structured reflective surface for coupling input/output of an optical fiber Download PDF

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Publication number
US20130322818A1
US20130322818A1 US13/786,448 US201313786448A US2013322818A1 US 20130322818 A1 US20130322818 A1 US 20130322818A1 US 201313786448 A US201313786448 A US 201313786448A US 2013322818 A1 US2013322818 A1 US 2013322818A1
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US
United States
Prior art keywords
optical fiber
reflective surface
structured reflective
coupling device
optical
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US13/786,448
Other languages
English (en)
Inventor
Shuhe LI
Robert Ryan Vallance
King-Fu Hii
Matthew GEAN
Michael K. Barnoski
Rand Dannenberg
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Cudoquanta AG
Senko Advanced Components Inc
Original Assignee
Nanoprecision Products Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nanoprecision Products Inc filed Critical Nanoprecision Products Inc
Priority to US13/786,448 priority Critical patent/US20130322818A1/en
Priority to CN201380025961.1A priority patent/CN104335089B/zh
Priority to JP2015505918A priority patent/JP2015513125A/ja
Priority to RU2014144532A priority patent/RU2638979C1/ru
Priority to KR1020147031247A priority patent/KR20140146647A/ko
Priority to EP13725854.7A priority patent/EP2836865B1/en
Priority to CA2869678A priority patent/CA2869678A1/en
Priority to US13/861,273 priority patent/US20130294732A1/en
Priority to PCT/US2013/036227 priority patent/WO2013155337A1/en
Priority to AU2013245808A priority patent/AU2013245808B2/en
Priority to MX2014012166A priority patent/MX338574B/es
Assigned to NANOPRECISION PRODUCTS, INC. reassignment NANOPRECISION PRODUCTS, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DANNENBERG, RAND, GEAN, Matthew, HII, KING-FU, BARNOSKI, MICHAEL K., LI, Shuhe, VALLANCE, ROBERT RYAN
Publication of US20130322818A1 publication Critical patent/US20130322818A1/en
Priority to US14/695,008 priority patent/US20150355420A1/en
Priority to US14/714,247 priority patent/US20160377821A1/en
Priority to US14/714,211 priority patent/US9782814B2/en
Priority to US15/077,816 priority patent/US20160274318A1/en
Priority to US15/077,902 priority patent/US9851511B2/en
Priority to US15/135,464 priority patent/US20160238803A1/en
Priority to US15/135,466 priority patent/US10718914B2/en
Priority to US15/668,670 priority patent/US20180081132A1/en
Priority to US15/726,324 priority patent/US10413953B2/en
Assigned to LAKE VIEW AG reassignment LAKE VIEW AG SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: NANOPRECISION PRODUCTS, INC.
Priority to US15/849,441 priority patent/US10274683B2/en
Assigned to LAKE VIEW AG reassignment LAKE VIEW AG SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: NANOPRECISION HOLDING COMPANY, INC., NANOPRECISION PRODUCTS, INC.
Priority to JP2018129579A priority patent/JP6791910B2/ja
Assigned to LAKE VIEW AG reassignment LAKE VIEW AG SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: NANOPRECISION HOLDING COMPANY, INC., NANOPRECISION PRODUCTS, INC.
Assigned to LAKE VIEW AG reassignment LAKE VIEW AG SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: NANOPRECISION HOLDING COMPANY, INC., NANOPRECISION PRODUCTS, INC.
Priority to US16/372,361 priority patent/US20190391345A1/en
Priority to US16/372,377 priority patent/US10754110B2/en
Priority to US16/372,374 priority patent/US20200003973A1/en
Priority to US16/388,741 priority patent/US20200116960A1/en
Priority to US16/450,746 priority patent/US10754107B2/en
Assigned to LAKE VIEW AG reassignment LAKE VIEW AG SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: NANOPRECISION HOLDING COMPANY, INC., NANOPRECISION PRODUCTS, INC.
Assigned to LAKE VIEW AG reassignment LAKE VIEW AG ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: NANOPRECISION HOLDING COMPANY, INC., NANOPRECISION PRODUCTS, INC.
Assigned to CUDOQUANTA FLORIDA, INC. reassignment CUDOQUANTA FLORIDA, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CUDOQUANTA AG
Assigned to CUDOQUANTA AG reassignment CUDOQUANTA AG ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LAKE VIEW AG
Priority to US16/933,899 priority patent/US11892691B2/en
Priority to US16/999,021 priority patent/US11803020B2/en
Priority to US17/203,565 priority patent/US20220026649A1/en
Assigned to SENKO ADVANCED COMPONENTS, INC. reassignment SENKO ADVANCED COMPONENTS, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CUDOQUANTA FLORIDA, INC.
Abandoned legal-status Critical Current

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Classifications

    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24—Coupling light guides
    • G02B6/42—Coupling light guides with opto-electronic elements
    • G02B6/4201—Packages, e.g. shape, construction, internal or external details
    • G02B6/4204—Packages, e.g. shape, construction, internal or external details the coupling comprising intermediate optical elements, e.g. lenses, holograms
    • G02B6/4214—Packages, e.g. shape, construction, internal or external details the coupling comprising intermediate optical elements, e.g. lenses, holograms the intermediate optical element having redirecting reflective means, e.g. mirrors, prisms for deflecting the radiation from horizontal to down- or upward direction toward a device
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24—Coupling light guides
    • G02B6/26—Optical coupling means
    • G02B6/262—Optical details of coupling light into, or out of, or between fibre ends, e.g. special fibre end shapes or associated optical elements
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24—Coupling light guides
    • G02B6/42—Coupling light guides with opto-electronic elements
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24—Coupling light guides
    • G02B6/42—Coupling light guides with opto-electronic elements
    • G02B6/4201—Packages, e.g. shape, construction, internal or external details
    • G02B6/4219—Mechanical fixtures for holding or positioning the elements relative to each other in the couplings; Alignment methods for the elements, e.g. measuring or observing methods especially used therefor
    • G02B6/4236—Fixing or mounting methods of the aligned elements
    • G02B6/424—Mounting of the optical light guide
    • G02B6/4243—Mounting of the optical light guide into a groove
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24—Coupling light guides
    • G02B6/42—Coupling light guides with opto-electronic elements
    • G02B6/4201—Packages, e.g. shape, construction, internal or external details
    • G02B6/4256—Details of housings
    • G02B6/4262—Details of housings characterised by the shape of the housing
    • G02B6/4263—Details of housings characterised by the shape of the housing of the transisitor outline [TO] can type
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24—Coupling light guides
    • G02B6/42—Coupling light guides with opto-electronic elements
    • G02B6/4295—Coupling light guides with opto-electronic elements coupling with semiconductor devices activated by light through the light guide, e.g. thyristors, phototransistors
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24—Coupling light guides
    • G02B6/42—Coupling light guides with opto-electronic elements
    • G02B6/4201—Packages, e.g. shape, construction, internal or external details
    • G02B6/4204—Packages, e.g. shape, construction, internal or external details the coupling comprising intermediate optical elements, e.g. lenses, holograms
    • G02B6/4206—Optical features

Definitions

  • the present invention relates to fiber optic signal transmission, in particular a device for physically and optically coupling an optical fiber for routing optical signals.
  • optical signals are transmitted over optical fibers, through a network of optical fibers and associated connectors and switches.
  • the optical fibers demonstrate a significantly higher bandwidth data transmission capacity and lower signal losses compared to copper wires for a given physical size/space.
  • optical signals and electrical signals take place beyond the terminating end of the optical fiber.
  • light from the optical fiber is detected by a transducing receiver and converted into an electrical signal for further data processing downstream (i.e., optical-to-electrical conversion).
  • electrical signals are converted into light to be input into the optical fiber by a transducing transmitter (i.e., electrical-to-optical conversion).
  • optical elements such as lenses are required to collimate and/or focus light from a light source (e.g., a laser) into the input end of the optical fiber, and to collimate and/or focus light from the output end of the optical fiber to a photo diode detector.
  • a light source e.g., a laser
  • optical fibers must be precisely aligned at high tolerance to the transmitters and receivers, so that the optical fibers are precisely aligned to the optical elements supported with respect to the transmitters and receivers.
  • the transmitters and receivers are provided with coupling structures having connection ports to which optical fibers are coupled using connectors terminating the optical fibers.
  • optical fibers are brittle, they must be handled with care during and after physical connection to the transmitter and receiver structures.
  • the transmitters and receivers and associated structures having the connection ports are therefore generally bulky, which take up significant space, thereby making them not suitable for use in smaller electronic devices.
  • the coupling structure for optical fibers and transmitters and receivers are generally quite expensive and comparatively large in size for a given port count.
  • the present invention provides a coupling device for physically and optically coupling an input/output end of an optical fiber for routing optical signals.
  • the device may be implemented for physically and optically coupling an optical fiber to an optical receiver and/or transmitter, which improves manufacturability, ease of use and reliability at reduced costs, thereby overcomes many of the drawbacks of the prior art structures.
  • the coupling device includes a structured surface that functions as an optical element that directs light to/from the input/output ends of the optical fiber by reflection (which may also include deflection and diffraction of incident light).
  • the coupling device also includes an optical fiber retention structure, which securely and accurately aligns the optical fiber with respect to the structured reflective surface.
  • the fiber retention structure includes at least one groove (or one or more grooves) that positively receives the optical fiber in a manner with the end of the optical fiber at a defined distance to and aligned with the structured reflective surface. The location and orientation of the structured reflective surface is fixed in relation to the fiber retention structure.
  • the fiber retention structure and the structured reflective surface are defined on the same (e.g., monolithic) structure of the coupling device. In an alternate embodiment, the fiber retention structure and the structure reflective surface are defined on separate structures that are coupled together to form the coupling device.
  • the structured reflective surface may be configured to be flat, concave or convex.
  • the structured reflective surface has a smooth surface with mirror finish. It may instead be a textured surface that is reflective.
  • the structured reflective surface may have a uniform surface characteristic, or varying surface characteristics, such as varying degree of smoothness and/or textures, or a combination of various regions of smooth and textured surfaces making up the structured reflective surface.
  • the structured reflective surface may have a surface profile and/or optical characteristic corresponding to at least one of the following equivalent optical element: mirror, focusing lens, diverging lens, diffraction grating, or a combination of the foregoing.
  • the structure reflective surface may have more than one region corresponding to a different equivalent optical element (e.g., a central region that is focusing surrounded by an annular region that is diverging).
  • the structured reflective surface is defined on an opaque material that does not transmit light through the surface.
  • the structured reflective surface and fiber retention structure are defined by an open structure, which lends itself to mass production processes such as stamping, which are low cost, high throughput processes.
  • the structured reflective surface and the fiber retention grooves are formed by stamping a metal material.
  • the metal material may be chosen to have high stiffness (e.g., stainless steel), chemical inertness (e.g., titanium), high temperature stability (nickel alloy), low thermal expansion (e.g., Invar), or to match thermal expansion to other materials (e.g., Kovar for matching glass).
  • the material may be a hard plastic or other hard polymeric material.
  • the coupling device may be attached to an optical transmitter and/or receiver, with the structured reflective surface aligned to the light source (e.g., a laser) in the transmitter or to the detector (e.g., a photo diode) in the receiver.
  • the transmitter/receiver may be hermetically sealed to the coupling device.
  • the transmitter/receiver may be provided with conductive contact pads for electrical coupling to external circuitry. Given the fixed structured reflective surface and the fiber retention structure are precisely defined on the same coupling device, by aligning the light source in the transmitter or the light detector in the receiver to the structured reflective surface in the coupling device, the light source/detector would be precisely aligned to the input/output end of the optical fiber.
  • a method of precise alignment of the transmitter/receiver to the coupling device comprises superimposing complementary alignment marks provided on the transmitter/receiver and the coupling device.
  • an optical fiber is structured as an active optical cable (AOC), which is a cable known in the art to have a transmitter at one terminal end of the optical fiber for electrical-to-optical conversion, and a receiver at another terminal end of the optical fiber for optical-to-electrical conversion.
  • AOC active optical cable
  • the coupling device in accordance with the present invention overcomes many of the deficiencies of the prior art, which provides ease of use and high reliability with low environmental sensitivity, and which can be fabricated at low cost.
  • the inventive coupling device may be configured to support a single or multiple fibers, for optical input, optical output or both (for bi-directional data communication).
  • FIG. 1 is a schematic diagram of the configuration of data transmission over an optical fiber, in which the coupling device of the present invention is implemented.
  • FIG. 2 is a schematic diagram illustrating the optical illumination pattern at the input end of the optical fiber.
  • FIG. 3 is a schematic diagram illustrating the optical illumination pattern at the output end of the optical fiber.
  • FIG. 4 is a schematic diagram illustrating the footprint of illumination on the structured reflective surfaces at the input end and the output end.
  • FIGS. 5A and 5B are schematic diagrams illustrating forming of a flat mirror with a spherical punch having a smooth flat surface
  • FIG. 5C is a photographic image of a flat mirror formed as a result.
  • FIG. 6 is a perspective view of the punch geometry for stamping a groove and a structured surface profile in the coupling device.
  • FIG. 7A is a sectional view along a longitudinal axis of the optical fiber;
  • FIG. 7B is a perspective sectional view thereof.
  • FIG. 8A is a perspective view of an integrated transmitter/receiver module in accordance with one embodiment of the present invention
  • FIG. 8B is a perspective view of the transmitter in accordance with one embodiment of the present invention
  • FIG. 8C is a perspective view of the receiver in accordance with one embodiment of the present invention.
  • FIG. 9 is a perspective view of an active optical cable (AOC) in accordance with one embodiment of the present invention.
  • FIG. 10A is a further embodiment of a coupling device having an alignment mark
  • FIG. 10B is a further embodiment of a transmitter/receiver.
  • FIG. 11A schematically illustrates an assembly stand and assembling process including alignment, in accordance with one embodiment of the present invention
  • FIG. 11B illustrates top view of a VCSEL provided with alignment dots in accordance with one embodiment of the present invention
  • FIG. 11C illustrates the rotary arm of the assembly stand swung to place a transmitter on top of a coupling device, in accordance with one embodiment of the present invention.
  • FIG. 1 schematically illustrates the configuration of data link for transmitting information over an optical fiber, in which the coupling device of the present invention is implemented. For simplicity, only some of the basic elements are included in FIG. 1 to explain the invention.
  • the terminating end sections of the optical fibers 10 are directed at structured reflective surfaces 12 and 14 .
  • a transmitter 16 having a light source e.g., a laser, such as a VCSEL—Vertical Cavity Surface-Emitting Laser
  • the collimated light output of the transmitter is directed at the structured reflective surface 12 of a coupling device in accordance with the present invention, which focuses light at the input end 17 of the optical fiber 10 .
  • Light signals are transmitted through the optical fiber 10 , and output to the structured reflective surface 14 in another coupling device in accordance with the present invention, which focuses the output light to an optical detector (e.g., a PIN photo diode) in a receiver 18 .
  • the receiver converts optical signals into electrical signals.
  • data is transmitted via optical signals over the optical fiber 10 , and recovered as electrical signals at the receiver 18 corresponding to the input data.
  • the optical fiber may be a 50/125 graded index optical fiber, with a numerical aperture (NA) of 0.2+/ ⁇ 0.015.
  • the structured reflective surfaces 12 and 14 are configured as concave mirrors, having an aperture width not exceeding 250 ⁇ m in order to match the standard pitch between two optical fibers in a ribbon cable.
  • the optical axis of the concave mirrors are aligned with the axis of the optical fiber 10 .
  • the ends 17 and 19 (flat or angled-polished end faces) of the optical fibers are at an effective distance (along the optical axis) of about 0.245 mm from the respective structured reflective surfaces 12 and 14 .
  • the light source in the transmitter 16 and the optical detector in the receiver 18 are at an effective distance (along the optical axis) of about 0.1 mm from the respective structured reflective surfaces 12 and 14 .
  • the optical source may be a VCSEL, having 850 nm wavelength, 6 mW optical output power, and 20 to 30 degrees beam divergence.
  • the optical detector may be a PIN photo diode with an active area of about 70 ⁇ m diameter.
  • FIGS. 2 and 3 further schematically illustrate the optical illumination pattern at the respective input and output of the optical fiber 10 .
  • FIG. 4 schematically illustrates the footprint of illumination on the structured reflective surfaces 12 and 14 .
  • the concave mirrors defined by these reflective surfaces can have the same shape, but the size of both mirrors is set by larger spot size on the mirror at the output/receiver end.
  • the mirrors may be 170 ⁇ m, with the spot size at the input/transmitter (Tx) end being 64 ⁇ m, and the spot size at the output/receiver (Rx) end being 108 ⁇ m.
  • the structured reflective surface may be formed by precision stamping a metal material.
  • FIG. 5 schematically illustrates forming a flat mirror with a spherical punch with a polished flat surface.
  • a precision stamping process and apparatus has been disclosed in U.S. Pat. No. 7,343,770, which was commonly assigned to the assignee of the present invention. This patent is fully incorporated by reference as if fully set forth herein.
  • the process and stamping apparatus disclosed therein may be adapted to precision stamping the features of the coupling device of the present invention (including the structured reflective surface and optical fiber retention structure disclosed below).
  • the stamping process and system can produce parts with a tolerance of at least 1000 nm.
  • the coupling device includes an optical fiber retention structure, which securely and accurately aligns the optical fiber 10 with respect to the structured reflective surface 13 .
  • the structured reflective surface and fiber retention structure are defined by an open structure, which lends itself to mass production processes such as stamping, which are low cost, high throughput processes.
  • FIG. 7A is a sectional view taken along the longitudinal axis of the optical fiber 10 .
  • FIG. 7B is a perspective section view taken along the longitudinal axis of the optical fiber 10 .
  • the fiber retention structure includes a groove 22 that positively receives the optical fiber in a manner with the end of the optical fiber 10 at a defined distance to and aligned with the structured reflective surface 13 .
  • the location and orientation of the structured reflective surface 13 is fixed in relation to the fiber retention structure.
  • the fiber retention structure and the structured reflective surface are defined on the same (e.g., monolithic) base 26 of the coupling device.
  • the fiber retention structure and the structure reflective surface are defined on separate structures that are coupled together to form the coupling device.
  • the groove 22 has a section 24 defining a space between the end face 15 of the optical fiber 10 .
  • the distance of the flat surface of the VCSEL from the top surface 29 of the base 26 would be about 37.5 ⁇ m.
  • the groove 22 is structured to securely retain the fiber 10 (bare section with cladding exposed, without protective buffer and jacket layers) by clamping the fiber 10 , e.g., by a mechanical or interference fit (or press fit).
  • the interference fit assures that the fiber 10 is clamped in place and consequently the position and orientation of the fiber 10 is set by the location and longitudinal axis of the groove 22 .
  • the groove 22 has a U-shaped cross-section that snuggly receive the bare optical fiber 10 (i.e., with the cladding exposed, without the buffer and protective layers).
  • the sidewalls of the groove 22 are substantially parallel, wherein the opening of the groove may be slightly narrower than the parallel spacing between the sidewalls (i.e., with a slight C-shaped cross-section) to provide additional mechanical or interference fit for the fiber 10 .
  • Further details of the open groove structure can be found in copending U.S. patent application Ser. No. 13/440,970 filed on Apr. 5, 2012, which is fully incorporated by reference herein.
  • the base 26 having the groove 22 is effectively a one-piece open ferrule supporting the optical fiber 10 in precise location and alignment with the structured reflective surface 13 .
  • the location of the structured reflective surface 13 is fixed with respect to the groove 22 and the shoulder 27 , and hence fixed with respect to the end face of the optical fiber 10 .
  • the structured reflective surface 13 is not supported on a moving part and does not involve any moving part.
  • the base 26 of the coupling device is formed of a metal material.
  • the metal material may be chosen to have high stiffness (e.g., stainless steel), chemical inertness (e.g., titanium), high temperature stability (nickel alloy), low thermal expansion (e.g., Invar), or to match thermal expansion to other materials (e.g., Kovar for matching glass).
  • the base 26 may be formed of a metal such as aluminum or copper, which offer hier optical reflectivity. The reflectivity can also be achieved by plating materials such as gold, silver, nickel, aluminum, etc. onto the body 26 .
  • the material may be a hard plastic or other hard polymeric material.
  • FIG. 6 illustrates a punch 200 configured for stamping the groove 22 and structured reflective surface 13 in the base 26 .
  • the punch 200 has a convex surface profile that is essentially the inverse of the structured reflective surface and the groove.
  • the surface profile of the punch 200 conforms to the features to be stamped.
  • the base 46 has raised sidewalls 37 defining a cavity 36 in which the structured reflective surface 43 and grooves are located.
  • the cavity 36 provides space for accommodating the height of the IC chip mounted on the circuit board 51 .
  • the height of the sidewalls 37 defines the distance between the light source/detector in the transmitter/receiver 38 and the structured reflective surface 43 in the coupling device 39 .
  • the light source/detector would be precisely aligned to the input/output end of the optical fiber.
  • transmitter/receiver and coupling device may be perceived to be an integrated transmitter/receiver module that includes a structured reflective surface and an integral coupling structure that aligns an optical fiber to the structured reflective surface.
  • an optical fiber is structured as an active optical cable (AOC), which is a cable known in the art to have a transmitter at one terminal end of the optical fiber for electrical-to-optical conversion, and a receiver at another terminal end of the optical fiber for optical-to-electrical conversion.
  • AOC active optical cable
  • FIG. 9 illustrates an embodiment of an AOC 48 that adopts the transmitter/receiver module 50 in accordance with the present invention.
  • the AOC 48 essentially includes the components illustrated in FIG. 1 .
  • the AOC 48 includes an optical fiber (bare fiber 10 and protective layers), a transmitter module 50 corresponding to the combination of transmitter 16 and a coupling device having the structured reflective surface 12 and a fiber retention structure discussed above which supports the end 17 of the fiber 10 , a receiver module 50 corresponding to the combination of receiver 18 and a coupling device having the structured reflective surface 14 and a fiber retention structure discussed above which supports the end 19 of the fiber 10 .
  • FIGS. 10 and 11 illustrates an embodiment of an assembling process, including precise alignment of the transmitter/receiver to the coupling device by superimposing complementary alignment marks provided on the transmitter/receiver and the coupling device.
  • FIG. 10A is another embodiment of a coupling device 46 ′ which is similar to FIG. 8C , except omitting raised sidewalls of the coupling device.
  • An alignment mark is provided on the top surface of the base 46 ′ of the optical coupling 39 ′.
  • the base 46 ′ precisely aligns the optical fiber 10 held in a groove, with respect to the structured reflective surface 43 ′.
  • the alignment mark comprises three dots 64 (which may be dimples produced by the stamping process forming the groove and structured reflective surface) arranged in an L-configuration around the structured reflective surface 43 ′, thus providing spatial alignment in two axis/directions.
  • the alignment dots 64 are spaced so that they correspond to certain features on the light source/detector on the transmitter/receiver.
  • FIG. 11B represents the top view of the square top surface 72 of a VCSEL 70 .
  • the VCSEL 70 has an output area 71 that is offset closer to one corner of the square top surface 72 .
  • FIG. 10 illustrates another embodiment of the transmitter 38 ′.
  • the base 150 ′ has raised sidewalls having a groove relief 79 to accommodate the extra thickness of the protective layer 11 of the optical fiber 10 .
  • the VCSEL 70 is mounted on a circuit board 51 ′.
  • FIG. 11A schematically illustrates an assembly stand 80 including an alignment system that adopts the above described alignment marks.
  • the assembly 80 stand includes a base 81 supporting an alignment stage 82 (e.g., X-Y translations in the X-Y horizontal plane and orthogonal Z-axis out of plane, and rotation about the Z-axis).
  • the assembly stand 80 further includes a rotary arm 83 having a pick-and-place head, which is supported to rotate about a bearing 84 to swing the arm onto over the alignment stage 82 .
  • the coupling device 39 ′ (or the coupling device 39 in FIGS. 8 and 9 ) is supported on the alignment stage 82 , with the alignment dots 64 in a horizontal plane.
  • the transmitter/receiver 38 ′ (or the transmitter/receiver 38 in FIGS. 8 and 9 ) is support by the pick-and-place head of the rotary arm 83 .
  • the square top surface 72 of the VCSEL 70 is in a vertical plane.
  • the axis orthogonal to the plane of the square top surface 72 of the VCSEL 70 is orthogonal to the axis orthogonal to the plane of the alignment dots 64 .
  • Using a camera 86 and a beam splitter 85 provides for simultaneous imaging of both the square top surface 72 of the VCSEL 70 and the alignment dots 64 .
  • the image of the alignment dots 64 can be brought into alignment with the image of the square top surface 72 , as shown in FIG. 11B .
  • the rotary arm 83 is then swung to place the transmitter 38 ′ on top of the coupling device 39 ′, as shown in FIG. 11C .
  • the transmitter 38 ′ and the coupling device 39 ′ are joined by, for example, laser welding, laser assisted soldering, or infrared soldering.
  • the coupling device in accordance with the present invention overcomes many of the deficiencies of the prior art, which provides ease of use and high reliability with low environmental sensitivity, and which can be fabricated at low cost.
  • the inventive coupling device may be configured to support a single or multiple fibers, for optical input, optical output or both (for bi-direction data communication).
  • transmitter/receiver and coupling device may be instead perceived to be an integrated transmitter/receiver module that includes one or more light sources/detectors, an integral coupling structure that includes one or more structured reflective surfaces and aligns one or more optical fibers to the structured reflective surfaces.
  • the structured reflective surface may be configured to be flat, concave or convex, or a combination of such to structure a compound reflective surface.
  • the structured reflective surface has a smooth (polished) mirror surface. It may instead be a textured surface that is reflective.
  • the structured reflective surface may have a uniform surface characteristic, or varying surface characteristics, such as varying degree of smoothness and/or textures across the surface, or a combination of various regions of smooth and textured surfaces making up the structured reflective surface.
  • the structured reflective surface may have a surface profile and/or optical characteristic corresponding to at least one of the following equivalent optical element: mirror, focusing lens, diverging lens, diffraction grating, or a combination of the foregoing.
  • the structure reflective surface may have a compound profile defining more than one region corresponding to a different equivalent optical element (e.g., a central region that is focusing surrounded by an annular region that is diverging).
  • the structured reflective surface is defined on an opaque material that does not transmit light through the surface.

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Optical Couplings Of Light Guides (AREA)
US13/786,448 2012-03-05 2013-03-05 Coupling device having a structured reflective surface for coupling input/output of an optical fiber Abandoned US20130322818A1 (en)

Priority Applications (30)

Application Number Priority Date Filing Date Title
US13/786,448 US20130322818A1 (en) 2012-03-05 2013-03-05 Coupling device having a structured reflective surface for coupling input/output of an optical fiber
AU2013245808A AU2013245808B2 (en) 2012-04-11 2013-04-11 Hermetic optical fiber alignment assembly having integrated optical element
MX2014012166A MX338574B (es) 2012-04-11 2013-04-11 Ensamble de alineacion de fibra optica hermetico que tiene elemento optico integrado.
RU2014144532A RU2638979C1 (ru) 2012-04-11 2013-04-11 Герметическая сборка для выравнивания оптического волокна, имеющая интегрированный оптический элемент
KR1020147031247A KR20140146647A (ko) 2012-04-11 2013-04-11 통합형 광학 요소를 갖는 밀폐식 광섬유 정렬 조립체
EP13725854.7A EP2836865B1 (en) 2012-04-11 2013-04-11 Hermetic optical fiber alignment assembly having integrated optical element
CA2869678A CA2869678A1 (en) 2012-04-11 2013-04-11 Hermetic optical fiber alignment assembly having integrated optical element
US13/861,273 US20130294732A1 (en) 2012-03-05 2013-04-11 Hermetic optical fiber alignment assembly having integrated optical element
PCT/US2013/036227 WO2013155337A1 (en) 2012-04-11 2013-04-11 Hermetic optical fiber alignment assembly having integrated optical element
CN201380025961.1A CN104335089B (zh) 2012-04-11 2013-04-11 具有集成光学元件的密闭式光纤对准组件
JP2015505918A JP2015513125A (ja) 2012-04-11 2013-04-11 一体型光学素子を有する密閉型光ファイバ位置合わせ組立体
US14/695,008 US20150355420A1 (en) 2012-03-05 2015-04-23 Coupling device having a stamped structured surface for routing optical data signals
US14/714,247 US20160377821A1 (en) 2012-03-05 2015-05-15 Optical connection of optical fibers to grating couplers
US14/714,211 US9782814B2 (en) 2012-03-05 2015-05-15 Stamping to form a composite structure of dissimilar materials having structured features
US15/077,816 US20160274318A1 (en) 2012-03-05 2016-03-22 Optical bench subassembly having integrated photonic device
US15/077,902 US9851511B2 (en) 2012-03-05 2016-03-22 Axial preload for demountable connectors
US15/135,464 US20160238803A1 (en) 2012-03-05 2016-04-21 Coupling device having a structured reflective surface for coupling input/output of an optical fiber
US15/135,466 US10718914B2 (en) 2012-03-05 2016-04-21 Optoelectronic module assembly having an optical fiber alignment assembly coupled to an optoelectronic device assembly
US15/668,670 US20180081132A1 (en) 2012-03-05 2017-08-03 Coupling device having a structured reflective surface for coupling input/output of an optical fiber
US15/726,324 US10413953B2 (en) 2012-03-05 2017-10-05 Stamping to form a composite structure of dissimilar materials having structured features
US15/849,441 US10274683B2 (en) 2012-03-05 2017-12-20 Axial preload for demountable connectors
JP2018129579A JP6791910B2 (ja) 2012-04-11 2018-07-09 一体型光学素子を有する密閉型光ファイバ位置合わせ組立体
US16/372,374 US20200003973A1 (en) 2012-03-05 2019-04-01 Hermetic optical fiber alignment assembly having integrated optical element
US16/372,377 US10754110B2 (en) 2012-03-05 2019-04-01 Optical bench subassembly having integrated photonic device
US16/372,361 US20190391345A1 (en) 2012-03-05 2019-04-01 Coupling device having a stamped structured surface for routing optical data signals
US16/388,741 US20200116960A1 (en) 2012-03-05 2019-04-18 Optical connection of optical fibers to grating couplers
US16/450,746 US10754107B2 (en) 2012-03-05 2019-06-24 Coupling device having a structured reflective surface of stamped malleable metal for coupling input/output of an optical fiber
US16/933,899 US11892691B2 (en) 2012-03-05 2020-07-20 Hermetic optical fiber alignment assembly having integrated optical element
US16/999,021 US11803020B2 (en) 2012-03-05 2020-08-20 Optical bench subassembly having integrated photonic device
US17/203,565 US20220026649A1 (en) 2012-03-05 2021-03-16 Optical connection of optical fibers to grating couplers

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201261606885P 2012-03-05 2012-03-05
US13/786,448 US20130322818A1 (en) 2012-03-05 2013-03-05 Coupling device having a structured reflective surface for coupling input/output of an optical fiber

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
US14/714,211 Continuation-In-Part US9782814B2 (en) 2012-03-05 2015-05-15 Stamping to form a composite structure of dissimilar materials having structured features

Related Child Applications (2)

Application Number Title Priority Date Filing Date
US13/861,273 Continuation-In-Part US20130294732A1 (en) 2012-03-05 2013-04-11 Hermetic optical fiber alignment assembly having integrated optical element
US15/135,464 Continuation US20160238803A1 (en) 2012-03-05 2016-04-21 Coupling device having a structured reflective surface for coupling input/output of an optical fiber

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US20130322818A1 true US20130322818A1 (en) 2013-12-05

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US13/786,448 Abandoned US20130322818A1 (en) 2012-03-05 2013-03-05 Coupling device having a structured reflective surface for coupling input/output of an optical fiber
US15/135,464 Abandoned US20160238803A1 (en) 2012-03-05 2016-04-21 Coupling device having a structured reflective surface for coupling input/output of an optical fiber
US15/668,670 Abandoned US20180081132A1 (en) 2012-03-05 2017-08-03 Coupling device having a structured reflective surface for coupling input/output of an optical fiber
US16/450,746 Active US10754107B2 (en) 2012-03-05 2019-06-24 Coupling device having a structured reflective surface of stamped malleable metal for coupling input/output of an optical fiber

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US15/135,464 Abandoned US20160238803A1 (en) 2012-03-05 2016-04-21 Coupling device having a structured reflective surface for coupling input/output of an optical fiber
US15/668,670 Abandoned US20180081132A1 (en) 2012-03-05 2017-08-03 Coupling device having a structured reflective surface for coupling input/output of an optical fiber
US16/450,746 Active US10754107B2 (en) 2012-03-05 2019-06-24 Coupling device having a structured reflective surface of stamped malleable metal for coupling input/output of an optical fiber

Country Status (12)

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US (4) US20130322818A1 (sv)
EP (1) EP2823344B1 (sv)
JP (1) JP6273217B2 (sv)
KR (1) KR102116151B1 (sv)
CN (2) CN106842440A (sv)
AU (2) AU2013230056A1 (sv)
CA (1) CA2865800C (sv)
DK (1) DK2823344T3 (sv)
ES (1) ES2726541T3 (sv)
MX (1) MX338930B (sv)
RU (1) RU2649034C2 (sv)
WO (1) WO2013134326A1 (sv)

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US20200049907A1 (en) 2020-02-13
RU2014139853A (ru) 2016-04-27

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