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
  • G02B6/25—Preparing the ends of light guides for coupling, e.g. cutting
• • 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
  • G02B6/241—Light guide terminations
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B24—GRINDING; POLISHING
  • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
  • B24B19/00—Single-purpose machines or devices for particular grinding operations not covered by any other main group
  • B24B19/22—Single-purpose machines or devices for particular grinding operations not covered by any other main group characterised by a special design with respect to properties of the material of non-metallic articles to be ground
  • B24B19/226—Single-purpose machines or devices for particular grinding operations not covered by any other main group characterised by a special design with respect to properties of the material of non-metallic articles to be ground of the ends of optical fibres
• • 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
  • G02B6/255—Splicing of light guides, e.g. by fusion or bonding
  • G02B6/2552—Splicing of light guides, e.g. by fusion or bonding reshaping or reforming of light guides for coupling using thermal heating, e.g. tapering, forming of a lens on light guide ends
• • 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
  • G02B6/4201—Packages, e.g. shape, construction, internal or external details
  • G02B6/4202—Packages, e.g. shape, construction, internal or external details for coupling an active element with fibres without intermediate optical elements, e.g. fibres with plane ends, fibres with shaped ends, bundles
  • G02B6/4203—Optical features
• • 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
  • G02B6/4237—Welding
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01S—DEVICES USING THE PROCESS OF LIGHT AMPLIFICATION BY STIMULATED EMISSION OF RADIATION [LASER] TO AMPLIFY OR GENERATE LIGHT; DEVICES USING STIMULATED EMISSION OF ELECTROMAGNETIC RADIATION IN WAVE RANGES OTHER THAN OPTICAL
  • H01S5/00—Semiconductor lasers
  • H01S5/10—Construction or shape of the optical resonator, e.g. extended or external cavity, coupled cavities, bent-guide, varying width, thickness or composition of the active region
  • H01S5/14—External cavity lasers
  • H01S5/146—External cavity lasers using a fiber as external cavity
  • H01S5/147—External cavity lasers using a fiber as external cavity having specially shaped fibre, e.g. lensed or tapered end portion

Definitions

• optical-fiber light-transmission systems it is typically important to increase the coupling efficiency between some type of opto-electronic device, such as a light source or detector, and the optical fiber transmission media.
• opto-electronic device such as a light source or detector
• One of the most common applications is in communications systems, in which an optical signal, generated by a modulated semiconductor diode, laser diode light source, or a source with a separate modulator, is coupled into a fiber.
• the laser diode is usually a single-transverse-mode device, and the fiber only propagates a single mode.
• the optical signal is coupled from the end of the fiber to a detector, where it is converted back to an electrical signal.
• the laser diodes that are used to optically pump the fiber amplifiers.
• the pump light generated by the laser diode is coupled into a fiber for transmission to the fiber amplifier.
• the coupling issues typically surround the interface between the opto-electronic device and the end of a fiber in an opto-electronic module.
• the opto-electronic device laser diode or detector
• the substrate which is installed in the opto-electronic module.
• the end of a short length of specially sheathed optical fiber, termed the pigtail is brought into the module, aligned to the opto-electronic device, and secured by reflow soldering, laser welding, or some other technique.
• the simplest coupling approach is optical fiber pigtail cleaving, with butt coupling.
• the end of the optical fiber is cleaved to a vertical, clean, flat endface. This endface is then secured in the opto-electronic module as close as possible to the light- emitting facet of the opto-electronic device.
• the general technique is to place a convex lens at the end of the fiber pigtail so that more light is collected from the opto-electronic source into the fiber's core.
• One of the simplest techniques is to secure a micro-spherical bead to the end of the fiber to function as a lens.
• the end of the fiber is etched to have a concave surface, and then the micro- spherical bead is glued to the fiber's end.
• microlens endfaces are fashioned on the optical fiber pigtail.
• pulling involves drawing the fiber in a flame to create a necked-down region and then cleaving the fiber at this narrowed waist, possibly followed with flame fusing. This technique is simple, but the resulting lens has large deviations from a hyperbolic surface.
• fiber polishing involves using a motor-controlled jig to bring the end of the optical fiber pigtail in contact with a rotating abrasive wheel and polishing the endface to form the intended endface lens.
• the lenses have typically been formed with typically steep or obtuse vertex angles.
• Fiber pulling techniques yield a lens that deviates too strongly from the optimal hyperbolic endface.
• fiber endface etching is the easiest to perform. The major problem, however, arises in yield.
• etch rates for fiber pigtails vary from batch-to- batch.
• typically test etching must be performed to determine the optimal solution concentrations and etch times.
• the etched lens may not be concentric with respect to the optical fiber pigtail's core, which substantially impairs coupling efficiency to render the nonconcentric fibers useless.
• the present invention involves a number of innovations in optical fiber endface polishing that substantially increase coupling efficiency while simultaneously improving yield.
• the endface of the fiber is polished, preferably to form a frustum-like or pointed endface.
• it is fused, preferably in an arc fuser to form a smooth, rounded endface.
• the vertex angles used in most polishing techniques are too large. In this way, older fiber drawing techniques offered certain advantages.
• the endface of the fiber is polished to have an acute vertex angle, resulting in substantial improvements in coupling efficiency.
• the invention features an endface of an optical fiber.
• the endface has a frustum region, which is produced by polishing the endface. In order to produce the optimal rounded and smooth tip, however, the polished fiber is then fused.
• the polished frustum region is frusto-conical, or near conical.
• Such circular symmetry is desirable where the opto-electronic source has high far field symmetry as in the case with most modulated opto-electronic sources.
• the vertex angle of the polished frustum region is acute, preferably between 16° and 20°. Research has shown this to be the optimum range.
• an intermediate frustum region is preferably polished into the fiber.
• the invention concerns an optoelectronic module.
• This module contains an opto-electronic device, such as a laser diode or laser diode/modulator, or even an opto-electronic detector.
• An optical fiber in the form of a pigtail transmits the optical signal either from or to the opto-electronic device.
• This pigtail according to the invention, has an endface that has a polished frustum region and a fused tip.
• the invention also features a method for manufacturing a lens at the end of an optical fiber.
• the method comprises polishing the end while rotating the optical fiber around its axis. Then, according to the invention, the tip of the fiber is fused.
• the concentricity of the fiber is checked during the polishing step. Research has shown that the concentricity must be controlled in order to maximize the coupling efficiency. The lack of this control was one of the primary drawbacks associated with the fiber endface etching techniques.
• an endface with two or more discrete vertex angles is produced by polishing as the endface is placed in contact with a polishing wheel.
• Fig. 1 is a perspective, partial cutaway view of an opto-electronic module, illustrating an application of the present invention
• Figs. 3 A and 3B are schematic side and perspective views of an optical fiber polishing apparatus or jig according to the present invention.
• Figs. 4A is schematic cross-sectional view of an optical fiber illustrating a coarse polishing according to the present invention
• Figs. 4B is schematic cross-sectional view of an optical fiber illustrating a medium polishing according to the present invention
• Figs. 4C is schematic cross-sectional views of an optical fiber illustrating a fine polishing according to the present invention
• Fig. 5 A and 5B are images of a fiber endface after a two coarse polishings
• Fig. 6 is a top plan view showing polishing regions on the polishing wheel
• Figs. 7A, and 7B are images of the fiber endface after the finish polish at 500x magnification
• Fig. 8 is a side view of the endface in the arc fuser after polishing is complete, but before fusing;
• Fig. 9A and 9B are images of the finished, fused endface at 500x and lOOOx magnification;
• Fig. 10 is a graph of coupling efficiency as a function of fiber type illustrating the advantages of the inventive fiber lens manufacturing technique relative to other accepted techniques for lens manufacture.
• Fig. 1 shows an opto-electronic module 100 in which the inventive optical fiber is installed.
• the module 100 comprises a box-like package 110.
• a booted optical fiber pigtail 112 extends through a distal wall 111 of the package 110 and is secured and terminated to a usually thin-film substrate 114.
• the plastic jacket 102 is removed from the glass-silica fiber 104, which is then metalized.
• the metalized fiber is soldered to an adjustment tube 113.
• a bracket or clip 116 is used to secure the tube 113, and thus the optical fiber center 104 to the substrate 114.
• This bracket 116 can be welded, soldered, or otherwise secured to the substrate using known techniques, such that the optical fiber 104 is held by the bracket 116 on the substrate 114, with its endface 118 in proximity to and in a predetermined relationship with an opto-electronic device 115.
• the illustrated embodiment has four laser-weld points
• the opto-electronic device 115 is typically a diode, laser diode, LED, or laser-modulator system, but can also be a detector.
• the alignment is typically crucial requiring accuracies and life-time stabilities on the order of 0J-0.6 micrometers ( ⁇ m).
• Fig. 2 is a scale, side view of an optical fiber endface 118, which has been constructed according to the principles of the present invention.
• the optical fiber 104 is comprised of a core region 126, in which most of the optical power is transmitted and a cladding region 128 that confines the optical signal to and in a region surrounding the core.
• a cladding/core boundary or interface 130 separates these two concentric regions of the optical fiber 104 .
• the index profile is usually a step, as is common in single mode fibers.
• a lens is formed at the optical fiber endface 118.
• the endface 118 comprises a polished frustum region 120.
• This frustum region 120 is formed on the endface of the fiber by polishing and is created to be as concentric as possible with respect to the center axis 132 of the fiber 104.
• the frustum region is conical or near conically shaped, i.e., circularly symmetric.
• the aspect ratio of the cross-section of the polished frustum region is preferably between 1.5:1 to 1:1.
• an elliptical frustum region is implemented in the case of elliptical core fibers and/or where there is low the far-field circular symmetry in the source 115.
• the surface of the polished frustum region 120 does not extend into or invade the core 126 of the fiber.
• the polished frustum region 120 is polished into the fiber endface 118 such that the top frustum diameter "a" is equal to approximately three-four times the diameter "d" of the core 126.
• a fused frustum region 122 extends from the polished frustum region 120 towards the tip 124 of the endface 118.
• the fused frustum region is formed by a combination of polishing followed by the fusing of the fiber.
• the tip 124 of the endface is smooth spherical lens due to the glass's-surface tension during fusing.
• the fiber endface 118 has a very low angle. Specifically, the vertex angle of the polished is less than 25°, between 16°and 20°. Preferably, it is about 16°.
• the fused frustum region 122 has a somewhat larger vertex angle in the preferred embodiment. Specifically, it is less than 90°, and preferably less than 60°; in the illustrated embodiment, it is between 44° and 50°.
• the tip 124 is then fused to generate a rounded lens tip. As a result, the overall cross-section profile of the fiber endface 122 closely matches the ideal hyperbolic cross-section.
• Figs. 3A and 3B show the polishing device for forming a fiber endface as illustrated in Fig. 2.
• the fiber polishing device comprises a fiber rotating jig device 152.
• the jig device has a rigid barrel 150 through which the fiber pigtail extends 112. The barrel holds the fiber by its plastic jacket. This barrel is driven to rotate by a motor in the housing 151 to turn or rotate the fiber axially.
• the jig device 152 is supported on an arm 154 that rides in a track 156 so that the fiber 112 can be moved in and out of contact with polishing wheel 158.
• the fiber endface 118 is polished by driving the polishing wheel 158.
• the wheel is connected to a shaft 160, which is turned by a motor 162.
• the wheel face 158 is angled at 55° with respect to horizontal.
• the rigid barrel 150 is at 22° with respect to horizontal.
• the angle between the polishing wheel 158 and the rigid barrel 150 is a relatively obtuse 147°. As illustrated by the figure, however, the polishing angle is actually larger.
• the distance between the end of the barrel 150 and the closest point on the polishing wheel is 5.5 millimeters (mm). 9 mm of the pigtail 112, however, extends from the end of the barrel 150. This 9 mm of the pigtail 112 is unjacketed, i.e., only glass silica fiber 104.
• the fiber 104 bends upward, in the direction of wheel rotation so that there is a low angle between the end of the fiber and the wheel 158; the resiliency of the glass silica fiber 104 controls the polishing force.
• the cleaving the fiber for polishing at a distance 165 % of the distance from the fiber holder to the wheel results in shallow angles relative to the fiber transmission axis for out side radial position and steeper angles for polished surfaces closer to the fiber center. This difference between cleaved fiber and distance to wheel also compensates for any angular misalignment of the fiber in barrel 150. Further, the contact pressure between the endface and polishing wheel is dictated by fiber resiliency, and does not need to be actively controlled. Also, the length can be changed to modify and control polish angle
• Fig. 3B further illustrates the fiber polishing apparatus.
• the fiber endface 118 of the pigtail 120 contacts the polishing wheel 158 at a midpoint between its center and rim.
• the face of the polishing wheel preferably has two paper grits.
• Figs. 4A and 4B illustrate the polishing process according to the present invention, after the fiber is first cleaved and loaded into the fiber polishing jig 152.
• Fig. 4A illustrates the first stage of the coarse polishing sequence, which is performed on a coarser grit polishing paper of 9 ⁇ m. Specifically, for a given fiber endface 118, four positions (1, 2, 3, 4) are defined spaced at equal distances around its diameter. In the first step in the coarse polishing, position 1 is brought in contact with the polishing wheel, as illustrated by arrow 164. While in contact with the wheel, the fiber is rotated 15/8 turns as illustrated by arrow 166. Thereafter, the fiber is withdrawn from the wheel as illustrated by arrow 165.
• the fiber is rotated so that position 3 is first contacted with the polishing wheel (164) and again the fiber is rotated 1 and 5/8 turns starting at position 3 while in contact with the wheel (166). Then, in the third polishing step, the fiber is rotated so that position 4 will contact the wheel and the fiber is brought in contact with the rotating wheel. The fiber is again rotated 1 5/8 of a turn. Finally, the fiber is rotated such that position 2 will contact the wheel by the polishing jig's barrel. Thus, position 2 first contacts the wheel, and again, the fiber is rotated 1 and 5/8 turns while being polished.
• the coarse polish further contains steps 5-8 where the fiber is again rotated 1 5/8 turns as shown in Fig. 4A.
• the polishing is started at positions 1.5, 3.5, 2.5, and 4.5, respectively, and indicated by arrows 164, rotated through arcs as indicated by arrows 166, and then withdrawn from the wheel as indicated by arrows 165.
• Fig. 5 A shows a typical fiber endface after the first coarse polishing. There is still a substantial portion of the original cleaved endface remaining. If the diameter of the endface is greater than 14.5 ⁇ m, the coarse polishing is repeated until the endface is smaller than the 14.5 ⁇ m diameter..
• Fig. 5B shows a typical fiber endface after the second coarse polishing. Again, there is still a substantial, albeit smaller, portion of the original cleaved endface remaining. If the diameter of the endface is between 14.5 ⁇ m and 7 ⁇ m in diameter, a medium polish is performed. If the cleaved endface is less than 7 ⁇ m to non-existent, the fine polish is performed.
• Fig. 4B shows the medium polish process which is also perform on the 9 ⁇ m grit polishing paper.
• the initial points of contact, see arrows 164, for steps 1-8 are the same as the coarse polish, but the fiber is only rotated 5/8 of a turn, see arrows 166, before being withdrawn, see arrows 165.
• Fig. 4C shows the fine polish process, which is also performed on the 9 ⁇ m grit polishing paper.
• the initial points of contact, see arrows 164, for steps 1-8 are the same as the coarse polish, but the fiber is only rotated 3/8 of a turn, see arrows 166, before withdrawal from the wheel 158, see arrows 165.
• the medium and fine polish processes are performed until all of the cleaved endface is removed, i.e., the endface 118 has been over-polished.
• Critical to the coarse, medium, and fine polishing on the 9 ⁇ m grit polishing paper is the fact that the frustum region 120 is concentric with respect to the core 126 and fiber axis 132. In the preferred embodiment, this concentricity is confirmed for every stage of the polishing in order to ensure that it is being maintained. The concentricity is checked by illuminating the non-polished, distant end of the pigtail and viewing the polished endface. The coarse polishing can then modified to re-establish concentricity as required using an adaptive technique.
• a finish polish is performed on a fine grit paper 212 located on the same wheel as the coarse grit paper.
• This finish polish is the same as the fine polish illustrated in Fig. 4C, except for the use of a finer 3 um grit polishing surface.
• Fig. 6 illustrates where the polishing steps are performed in the polishing wheel 158.
• Region 170 shows the eight slots in which coarse grit polishing of a first fiber endface is performed.
• the eight slots correspond to the eight steps of the coarse, medium and fine polishing processes that take place on the coarse, 9 ⁇ m grit paper. As a result, the eight slots are reused for every successive coarse grit polishing of the same fiber.
• a second fiber is then polished on region 172, and so on working radially inward to at least a third region 174.
• the polishing wheel 158 comprises a 2 inch disk (3 um grit) 212 on top of 4 inch disk (9 um) 210.
• the finish polish is performed on a fine grit paper 212 located on the same wheel as the coarse grit paper. Thus the fiber does not need to be transferred to a new jig.
• the eight steps of the finish polish are performed in the eight slots 176. Every fiber is polished in the same fine grit slots 176.
• 3 um paper has more control over the concentricity of the endface. The 3 um paper also leaves side of lens with smoother finish.
• Figs. 7A and 7B show an endface after the finish polishing step.
• Fig. 8 shows the endface 118 in an arc fuser after the finish polishing steps but before is started.
• the fiber comprises the polished frustum region 120, and intermediate polished frustum region 122' having a vertex angle of about 80 degrees, and a conical tip having a vertex angle about 142 degrees.
• the intermediate frustum region 122' and the conical tip are created by the initial contact with the wheel and at withdrawal from the wheel during polishing.
• an electric current travels between electrodes 180 and 182 from current source 186.
• the endface is fused twice, with an axial rotation of 90 - 180 degrees between the first and second fusing. Surface tension of the melted glass forms a very systemic lens on polished end. This can compensate or repair slight imperfections in polished end.
• Fiber lens is positioned under 500X scope, with the transmission axis of the fiber pointed away from the microscope objective. By introducing white light to the through the other end of the fiber to operator can measure how concentric the lens sphere and the fiber transmission core is aligned.
• Figs. 9A and 9B show the fiber tip after fusing and in its finished state.
• Fig. 10 is a graph of coupling efficiency as a function of fiber type. As shown, using fiber types according to the present invention, fiber type #1, coupling efficiencies between 70 and 80% are achieved. As shown by fiber type #2, however, coupling efficiency falls to between 80 and 50% if the lens is formed off center or not concentrically with respect to the fiber center axis. The achieved coupling efficiencies, tightly bound between 70 and 80% compare favorably with etched fibers as illustrated by fiber type #5, where, although the average coupling efficiency is slightly higher, there is a larger standard deviation in the result. Consequently, according to the present invention, higher yields can be achieved because of the lower standard deviation in coupling efficiency with better predictability in the quality of the finished module.
• Average coupled power of fiber lenses made with this process are 74 % of the light from typical ridge waveguide 1300 nm and 1550 nm laser chips. Coupled efficiency of as high as 79 % have been found.
• the shape the coupling curves in X, Y and Z directions is similar to etched and fused fiber lenses.

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• Physics & Mathematics (AREA)
• General Physics & Mathematics (AREA)
• Optics & Photonics (AREA)
• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Plasma & Fusion (AREA)
• Optical Couplings Of Light Guides (AREA)
• Grinding And Polishing Of Tertiary Curved Surfaces And Surfaces With Complex Shapes (AREA)
• Light Guides In General And Applications Therefor (AREA)
• Optical Fibers, Optical Fiber Cores, And Optical Fiber Bundles (AREA)

Priority Applications (8)

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Publications (3)

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• 1998
  • 1998-11-10 US US09/189,644 patent/US6415087B1/en not_active Expired - Fee Related
• 1999
  • 1999-11-10 EP EP99971927A patent/EP1137959B1/en not_active Expired - Lifetime
  • 1999-11-10 BR BR9916739-5A patent/BR9916739A/pt not_active Application Discontinuation
  • 1999-11-10 CA CA002350533A patent/CA2350533A1/en not_active Abandoned
  • 1999-11-10 DE DE69905196T patent/DE69905196T2/de not_active Expired - Fee Related
  • 1999-11-10 AU AU14752/00A patent/AU1475200A/en not_active Abandoned
  • 1999-11-10 JP JP2000581485A patent/JP2002529785A/ja active Pending
  • 1999-11-10 MX MXPA01004455A patent/MXPA01004455A/es unknown
  • 1999-11-10 WO PCT/US1999/026621 patent/WO2000028360A2/en not_active Ceased
  • 1999-11-10 KR KR1020017005904A patent/KR20010080405A/ko not_active Withdrawn
  • 1999-11-10 CN CN99812885A patent/CN1325497A/zh active Pending

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