Manufacturing technique for optical fiber array

• US 6,799,370 B2
• Filed: 06/28/2001
• Issued: 10/05/2004
• Est. Priority Date: 06/28/2001
• Status: Active Grant

• Current Assignee: AL Cielo Ltd.
• Original Assignee: Chiaro Networks, Ltd.
• Inventors: Shekel, Eyal, Rephaeli, Eli
• Primary Examiner(s): Arbes, Carl J.
• Assistant Examiner(s): PHAN, THIEM D
• Application Number:
  US09/892,866
• Publication Number:
  US 20030002847A1
• Time in Patent Office: 1,195 Days
• Field of Search: 298/54, 298/50, 297/07, 297/20, 297/21, 385/90, 385/147
• US Class Current: 29/854
• CPC Class Codes: G02B 6/362 Vacuum holders for optical elements
• 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
• CPC Class Codes: G02B 6/3684 characterised by the manufacturing process of surface profiling of the supporting carrier manufacturing microsystems per se B81C1/00015
• CPC Class Codes: G02B 6/3837 forwarding or threading methods of light guides into apertures of ferrule centering means
• CPC Class Codes: Y10T 29/49162 by using wire as conductive path
• CPC Class Codes: Y10T 29/49169 Assembling electrical component directly to terminal or elongated conductor
• CPC Class Codes: Y10T 29/5303 Responsive to condition of work or product
• CPC Class Codes: Y10T 29/53087 with signal, scale, illuminator, or optical viewer
• CPC Class Codes: Y10T 29/53091 for work-holder for assembly or disassembly

Abstract

An improved manufacturing technique for optical fiber arrays employs optical feedback in a partially assembled unit using an inspection camera. This allows immediate reworking of a problematic part. In the present invention, a video microscope is used to check the alignment of the optical fiber array during the manufacturing process. After the optical fiber array has been glued or otherwise affixed, then an optical device may be used to measure the performance of the glued assembly.

Claims

1. Apparatus for manufacturing a fiberoptic device, comprising:

a fiber rotator mounted on a first stage, said fiber rotator carrying an optical fiber therein, and being operative to rotate said optical fiber about an optical axis thereof;

a second stage for holding a silicon slab;

a fiber gripping assembly disposed between said first stage and said second stage for gripping an intermediate portion of said optical fiber;

a first viewer directed toward said silicon slab along an axis that is orthogonal to said optical axis and orthogonal to a surface of said second stage upon which said silicon slab rests;

a second viewer directed toward an end face of said optical fiber alone said optical axis;

a weight, mounted on a third stage, a free end of said weight impinging on said optical fiber to urge an end portion of said optical fiber onto said silicon slab,

wherein responsive to views displayed by said first viewer and said second viewer, said first stage, said second stage, said fiber rotator, and said fiber gripping assembly are independently adjustable to establish said optical fiber in a desired position on said silicon slab, and

wherein said weight is pivotally mounted and pivots between a first position wherein said weight is in a non-contacting relationship with said optical fiber and a second position wherein said weight impinges on said optical fiber.

2. Apparatus for manufacturing a fiberoptic device, comprising:

a fiber rotator mounted on a first stage, said fiber rotator carrying an optical fiber therein, and being operative to rotate said optical fiber about an optical axis thereof;

a second stage for holding a silicon slab;

a fiber gripping assembly disposed between said first stage and said second stage for gripping an intermediate portion of said optical fiber;

a first viewer directed toward said silicon slab along an axis that is orthogonal to said optical axis and orthogonal to a surface of said second stage upon which said silicon slab rests;

a second viewer directed toward an end face of said optical fiber along said optical axis;

a weight, mounted on a third stage, a free end of said weight impinging on said optical fiber to urge an end portion of said optical fiber onto said silicon slab,

wherein responsive to views displayed by said first viewer and said second viewer, said first stage, said second stage, said fiber rotator, and said fiber gripping assembly are independently adjustable to establish said optical fiber in a desired position on said silicon slab, and

wherein said weight comprises;

a first weight that urges said end portion of said optical fiber into a groove formed in said silicon slab; and

a second weight that urges said end portion of said optical fiber onto a flat portion of said silicon slab.

3. Apparatus for manufacturing a fiberoptic device, comprising:

a fiber rotator mounted on a first stage, said fiber rotator carrying an optical fiber therein, and being operative to rotate said optical fiber about an optical axis thereof;

a second stage for holding a silicon slab;

a fiber gripping assembly disposed between said first stage and said second stage for gripping an intermediate portion of said optical fiber;

a first viewer directed toward said silicon slab along an axis that is orthogonal to said optical axis and orthogonal to a surface of said second stage upon which said silicon slab rests;

a second viewer directed toward an end face of said optical fiber along said optical axis;

wherein responsive to views displayed by said first viewer and said second viewer, said first stage, said second stage, said fiber rotator, and said fiber gripping assembly are independently adjustable to establish said optical fiber in a desired position on said silicon slab,

wherein said fiber gripping assembly is supplied by a vacuum line, and includes a channel formed therein for establishing fluid communication between said vacuum line and a tip portion of said fiber gripping assembly, and

wherein said optical fiber is held in said tip portion of said fiber gripping assembly by suction transmitted via said channel.

4. The apparatus according to claim 3, wherein said tip portion has a groove formed therein, and said optical fiber is received in said groove.

5. The apparatus according to claim 4, wherein said groove is dimensioned such that a surface of said optical fiber contacts a first side wall of said groove and contacts a second side wall of said groove.

6. Apparatus for manufacturing a fiberoptic device comprising:

a fiber rotator mounted on a first stage, said fiber rotator carrying an optical fiber therein, and being operative to rotate said optical fiber about an optical axis thereof;

a second stage for holding a silicon slab, said second stage being connected to a vacuum line and said silicon slab being exposed to vacuum transmitted via said vacuum line;

a fiber gripping assembly disposed between said first stage and said second stage for gripping an intermediate portion of said optical fiber;

a first viewer directed toward said silicon slab along an axis that is orthogonal to said optical axis and orthogonal to a surface of said second stage upon which said silicon slab rests;

a second viewer directed toward an end face of said optical fiber along said optical axis;

wherein responsive to views displayed by said first viewer and said second viewer, said first stage, said second stage, said fiber rotator, and said fiber gripping assembly are adjustable to establish said optical fiber in a desired position on said silicon slab.