Optical switch assembly with flex plate and method for making

• US 20050074201A1
• Filed: 09/30/2004
• Published: 04/07/2005
• Est. Priority Date: 12/20/2000
• Status: Active Grant

• Current Assignee: Samsung Electronics Co. Ltd.
• Original Assignee: David W Sherrer, John Fisher
• Inventors: Sherrer, David W., Fisher, John
• Granted Patent: US 7,079,725 B2
• Time in Patent Office: Days
• US Class Current: 385/17
• CPC Class Codes: G02B 6/3502 involving direct waveguide displacement, e.g. cantilever type waveguide displacement involving waveguide bending, or displacing an interposed waveguide between stationary waveguides
• CPC Class Codes: G02B 6/3504 Rotating, tilting or pivoting the waveguides, or with the waveguides describing a curved path rotary joint G02B6/3628
• CPC Class Codes: G02B 6/3522 the optical element enabling or impairing total internal reflection using evanescent coupling G02B6/3536
• CPC Class Codes: G02B 6/3536 involving evanescent coupling variation, e.g. by a moving element such as a membrane which changes the effective refractive index mode converters G02B6/14; adjustable lateral coupling between waveguides G02B6/283; electro- optical refractive index variations G02F1/0118
• CPC Class Codes: G02B 6/3546 NxM switch, i.e. a regular array of switches elements of matrix type constellation
• CPC Class Codes: G02B 6/3548 1xN switch, i.e. one input and a selectable single output of N possible outputs
• CPC Class Codes: G02B 6/3562 Switch of the bypass type, i.e. enabling a change of path in a network, e.g. to bypass a failed element in the network
• CPC Class Codes: G02B 6/3564 Mechanical details of the actuation mechanism associated with the moving element or mounting mechanism details
• CPC Class Codes: G02B 6/3566 involving bending a beam, e.g. with cantilever
• CPC Class Codes: G02B 6/3574 Mechanical force, e.g. pressure variations
• CPC Class Codes: G02B 6/3636 the mechanical coupling means being grooves G02B6/3652 takes precedence
• CPC Class Codes: G02B 6/3652 the additional structures being prepositioning mounting areas, allowing only movement in one dimension, e.g. grooves, trenches or vias in the microbench surface, i.e. self aligning supporting carriers

Abstract

An optical switch and method for assembling are described. Optical arrays are mounted on a flex plate with an interface between them. The direction of certain forces on the flex plate allows coupling/decoupling of the optical arrays. The flex plate includes an area which exhibits a different flex profile than the remainder of the flex plate and that is located beneath the optical arrays interface. Flexing of the flex plate optically couples the optical arrays. A tool with grooves is used to align the optical arrays relative to each other. The tool uses grooves and spheres to mate with the optical arrays in such a way as to provide an appropriate interface between the optical arrays.

Claims

1. A method for assembling an optical switch, comprising:

aligning at least a first optical array and a second optical array relative to one another with an alignment tool;

positioning said at least first and second optical arrays on a support structure;

immobilizing said at least first and second optical arrays relative to said support structure;

and

removing said tool from said at least first and second optical arrays.

2. The method of claim 1, wherein said aligning comprises:

mating at least a first groove on said tool with at least a first groove on said first optical array;

mating at least a second groove on said tool with at least a second groove on said second optical array; and

positioning a sphere within said mated first grooves and positioning a sphere within said mated second grooves.

3. The method of claim 1, wherein said positioning comprises locating on said support structure said at least first and second optical arrays with an interface therebetween.

4. The method of claim 3, wherein said locating is such that upon certain forces directed in certain directions and at certain locations of said support structure said interface is lessened and said at least first and second optical arrays are optically coupled.

5. The method of claim 1, wherein said immobilizing comprises adhering said at least first and second optical arrays to said support structure.

6. The method of claim 1, wherein said aligning comprises aligning said first and second optical arrays relative to a third optical array, said third optical array being interposed between said first and second optical arrays.

7. The method of claim 6, wherein said positioning comprises locating on said support structure said first, second and third optical arrays with a first interface between said first and third optical arrays and a second interface between said second and third optical arrays.

8. The method of claim 7, wherein said locating is such that upon certain forces directed in certain directions and at certain locations of said support structure, said first and second interfaces are lessened and said at least first and second optical arrays are optically coupled with said third optical array.

9. The method of claim 6, wherein said immobilizing comprises adhering said first, second and third optical arrays to said support structure.