Method of microfabrication

• US 6,126,775 A
• Filed: 01/12/1999
• Issued: 10/03/2000
• Est. Priority Date: 02/06/1998
• Status: Expired due to Fees

• Current Assignee: Lightwave technologies Inc.
• Original Assignee: Horizon Photonics, LLC
• Inventors: Sweeney, Richard J., Cullen, Robert R.
• Primary Examiner(s): Aftergut, Jeff H.
• Assistant Examiner(s): Haran, John T
• Application Number:
  US09/228,659
• Time in Patent Office: 630 Days
• Field of Search: 156/99, 156/250, 156/293, 156/297, 156/299, 156/303.1, 156/552, 359/280, 359/281, 359/282, 359/283, 359/900, 228/262.9, 430/320, 430/321
• US Class Current: 156/293
• CPC Class Codes: B29D 11/0073 Optical laminates
• CPC Class Codes: G02B 27/62 Optical apparatus specially adapted for adjusting optical elements during the assembly of optical systems
• CPC Class Codes: G02B 7/00 Mountings, adjusting means, or light-tight connections, for optical elements
• CPC Class Codes: G02F 1/093 used as non-reciprocal devices, e.g. optical isolators, circulators G02F1/0955 takes precedence
• CPC Class Codes: Y10S 359/90 Methods
• CPC Class Codes: Y10T 156/1052 with cutting, punching, tearing or severing
• CPC Class Codes: Y10T 156/1092 All laminae planar and face to face

Abstract

A temperature compensated optical isolator and a method of manufacturing optical assemblies. The isolator utilizes a bimetallic element to rotate a polarization element of the isolator in response to temperature variations. The isolator maintains an effectively constant isolation over a substantially wide temperature range. Advantageously, the isolator is simple, compact and a viable solution to a wide range of optical applications. The manufacturing method employs a lamination procedure to create an array of optics-receiving micro-fixtures. The method is well adapted for the automated manufacturing of optical assemblies. Desirably, the method provides for high speed, high volume production, thereby advantageously, maintaining low manufacturing costs.

Claims

1. A method of manufacturing optical assemblies, comprising the steps of:

creating in each of a plurality of sheets an array of frames;

stacking said sheets to form an array of fixtures comprising two or more pallets;

attaching an optical element in each of said fixtures to form an array of optical elements in each said two or more pallets;

layering said two or more pallets to form a lamination such that said optical elements are substantially aligned to create an array of said optical assemblies; and

removing said optical assemblies from said lamination.

2. The method of claim 1, wherein said step of stacking includes the step of laminating said plurality of sheets to form said array of fixtures in said two or more pallets.

3. The method of claim 2, wherein before said step of laminating is included the step of creating an array of frames in said plurality of sheets.

4. The method of claim 3, wherein said step of creating includes the step of photo-chemically etching to form said array of frames in said plurality of sheets.

5. The method of claim 3, wherein said step of creating includes the step of stamping to form said array of frames in said plurality of sheets.

6. The method of claim 2, wherein said step of laminating includes the step of brazing to form said array of fixtures in said two or more pallets.

7. The method of claim 1, wherein said step of attaching includes the step of gluing to form said array of optical elements in each said two or more pallets.

8. The method of claim 1, wherein said step of layering includes the step of welding to form said lamination including said array of said optical assemblies.

9. The method of claim 1, wherein said step of removing includes the step of either punching, shearing or stamping to form said optical assemblies.

10. The method of claim 1, wherein between said steps of layering and removing are included the steps of:

detaching one or more tab members connected to said array of said optical assemblies; and

affixing one or more bases to support one or more of said optical assemblies.

11. The method of claim 10, wherein said step of detaching includes the step of either punching, shearing or stamping.

12. The method of claim 10, wherein said step of affixing includes the step of welding.

13. The method of claim 10, wherein said one or more bases are generally yoke shaped.

14. The method of claim 10, further including the step of joining an optical component to said one or more bases.

15. A method of manufacturing a temperature compensated optical isolator, comprising the steps of:

forming an array of fixtures in a pair of first and second pallets;

attaching a polarizer in each said fixtures of said first pallet to form an array of said polarizers;

attaching a Faraday rotator in each said fixtures of said second pallet to form an array of said Faraday rotators;

layering said first and second pallets to form a lamination such that said array of said polarizers is substantially aligned with said array of said Faraday rotators to create an array of optical sub-assemblies;

affixing a base to each one of said optical sub-assemblies of said lamination;

joining a bimetallic element coupled to an analyzer to each one of said bases to form an array of said isolators; and

removing said isolators from said lamination.

16. The method of claim 15, wherein said step of forming includes the step of laminating two or more sheets to form said array of fixtures in said first pallet and said second pallet.

17. The method of claim 16, wherein before said step of laminating is included the step of creating an array of frames in said two or more sheets.

18. The method of claim 17, wherein said step of creating includes the step of photo-chemically etching to form said array of frames in said two or more sheets.

19. The method of claim 17, wherein said step of creating includes the step of stamping to form said array of frames in said two or more sheets.

20. The method of claim 16, wherein said step of laminating includes the step of brazing to form said array of fixtures in said first pallet and said second pallet.

21. The method of claim 15, wherein said steps of attaching include the steps of gluing to form said array of polarizers and said array of Faraday rotators.

22. The method of claim 15, wherein said step of layering includes the step of welding to form said lamination including said array of optical sub-assemblies.

23. The method of claim 15, wherein said step of affixing includes the step of welding.

24. The method of claim 15, wherein said step of joining includes the step of welding.

25. The method of claim 15, wherein said step of removing includes the step of either punching, shearing or stamping.

26. The method of claim 15, wherein between said steps of layering and affixing is included the step of detaching a plurality of tab members from said optical sub-assemblies.

27. The method of claim 26, wherein said step of detaching includes the step of either punching, shearing or stamping.

28. A method of fabricating assemblies of small components, comprising the steps of:

creating in each of a plurality of sheets an array of frames;

stacking said sheets to form a plurality of pallets, each including an array of fixtures;

affixing said components in said fixtures to form arrays of said components in said pallets;

stacking said pallets to form a laminate stack such that said components are substantially aligned to create an array of said assemblies; and

removing said assemblies from said laminate stack.

29. The method of claim 28, wherein said step of forming a plurality of pallets includes the step of laminating a plurality of sheets.

30. The method of claim 28, wherein said step of forming a plurality of pallets includes the step of molding.

31. The method of claim 28, wherein said fixtures comprise micro-fixtures.

32. A plurality of optical assemblies, comprising:

a plurality of optical elements; and

two or more pallets stacked together to form a plurality of fixtures, each fixture having an optical element therein, wherein said respective pallets are formed by stacking a plurality of sheets, each sheet having a plurality of frames therein, said sheets with said frames being aligned to form said fixtures and said pallets are stacked together such that said optical elements therein form stacks of optical elements to form said plurality of optical assemblies.