Method of micro-fabrication
First Claim
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1. A method of manufacturing optical assemblies, comprising the steps of:
- forming arrays of fixtures in a plurality of pallets;
attaching optical elements in said fixtures to form arrays of said optical elements in said pallets;
layering said pallets to form a lamination of pallets such that predetermined sets of said optical elements are substantially aligned to create an array of optical assemblies; and
removing said optical assemblies from said lamination of pallets.
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Abstract
A micro-fabrication method of manufacturing optical assemblies and a temperature compensated optical isolator. 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. 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.
31 Citations
72 Claims
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1. A method of manufacturing optical assemblies, comprising the steps of:
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forming arrays of fixtures in a plurality of pallets;
attaching optical elements in said fixtures to form arrays of said optical elements in said pallets;
layering said pallets to form a lamination of pallets such that predetermined sets of said optical elements are substantially aligned to create an array of optical assemblies; and
removing said optical assemblies from said lamination of pallets. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
detaching tab members connected to said optical assemblies; and
affixing bases to said optical assemblies to support said optical assemblies.
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13. The method of claim 12, wherein said step of detaching tab members includes the step of either punching, shearing or stamping.
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14. The method of claim 12, wherein said step of affixing bases includes the step of welding.
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15. The method of claim 12, wherein said bases are generally yoke shaped.
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16. The method of claim 12, further including the step of joining optical components to said bases.
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17. An optical assembly, comprising:
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a plurality of optical elements; and
a plurality of optic-receiving fixtures housing said optical elements, said fixtures being substantially aligned with one another so that said optical elements are substantially aligned with one another, said fixtures being laminated to form an optical assembly.
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18. A method of manufacturing a temperature compensated optical isolator, comprising the steps of:
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forming an array of fixtures in each one of a pair of first and second pallets;
attaching a polarizer in each fixture of said first pallet to form an array of polarizers;
attaching a Faraday rotator in each fixture of said second pallet to form an array of Faraday rotators;
layering said first and second pallets to form a lamination such that said array of polarizers is substantially aligned with said array of Faraday rotators to create an array of optical sub-assemblies;
aligning an analyzer connected to a bimetallic element with each of said optical sub-assemblies to form an array of optical isolators; and
removing said optical isolators from said lamination. - View Dependent Claims (19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32)
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33. A method of fabricating assemblies of components, comprising the steps of:
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forming a plurality of pallets each comprising 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 of pallets such that predetermined sets of said components are substantially aligned to create an array of said assemblies; and
removing said assemblies from said laminate stack of pallets. - View Dependent Claims (34, 35, 36, 37, 38)
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39. A method of fabricating assemblies of components, comprising the steps of:
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forming a plurality of pallets each comprising an array of fixtures with each fixture having an internal seating surface for receiving and supporting individual components;
attaching said components in said fixtures to form arrays of said components in said pallets;
laminating said pallets to form a laminated stack of pallets such that predetermined sets of said components are substantially aligned to create an array of said assemblies; and
detaching said assemblies from said laminated stack of pallets. - View Dependent Claims (40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54)
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55. A method of manufacturing assemblies of components, comprising the steps of:
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forming a plurality of pallets each comprising an array of fixtures;
affixing discrete components in each one of said fixtures to form arrays of said components in said pallets;
stacking said pallets to form a laminate stack of pallets such that predetermined sets of said components are substantially aligned to create an array of said assemblies; and
removing said assemblies from said laminate stack of pallets. - View Dependent Claims (56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70)
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71. An assembly of micro-components, comprising:
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a plurality of discrete components; and
a plurality of fixtures with each fixture having an internal seating surface supporting an individual component, each fixture being formed by aligning and stacking two or more frames, said fixtures being aligned and stacked together such that said components therein are aligned and stacked to form said assembly of micro-components.
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72. A method of manufacturing, comprising:
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providing plural pallets each of which comprises a plurality of discrete fixtures supported by respective support members in an array;
mounting respective discrete optical elements in said discrete fixtures;
aligning optical elements of one pallet with optical elements of another pallet to form an array of optical assemblies, said aligning comprising stacking said pallets; and
severing said support members to free said optical assemblies from said stacked pallets.
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Specification
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Current AssigneeLightwave technologies Inc.
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Original AssigneeHorizon Photonics, Inc.
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InventorsSweeney, Richard J., Cullen, Robert C.
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Primary Examiner(s)Aftergut, Jeff H.
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Assistant Examiner(s)Haran, John T.
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Application NumberUS09/481,625Time in Patent Office867 DaysField of Search156/99,250,256,293,297,299,303.1,552,563,564 228/262.9 430/320,321US Class Current156/293CPC Class CodesB29D 11/0073 Optical laminatesG02B 27/62 Optical apparatus specially...G02B 7/00 Mountings, adjusting means,...G02F 1/093 used as non-reciprocal devi...Y10T 156/1052 with cutting, punching, tea...Y10T 156/1092 All laminae planar and face...
