Optical device

• US 6,971,164 B2
• Filed: 01/28/2003
• Issued: 12/06/2005
• Est. Priority Date: 02/20/2001
• Status: Expired due to Fees

• Current Assignee: RPX Corporation
• Original Assignee: CyberOptics Corporation (Nordson Corporation)
• Inventors: Case, Steven K., Skunes, Timothy A., Mowry, Gregory S.
• Primary Examiner(s): Arbes, Carl J.
• Application Number:
  US10/352,795
• Publication Number:
  US 20040001674A1
• Time in Patent Office: 1,043 Days
• Field of Search: 297/40, 298/25, 298/32, 298/40, 385/49
• US Class Current: 29/840
• CPC Class Codes: G02B 6/255 Splicing of light guides, e.g. by fusion or bonding
• CPC Class Codes: G02B 6/2553 Splicing machines, e.g. optical fibre fusion splicer
• CPC Class Codes: G02B 6/2555 Alignment or adjustment devices for aligning prior to splicing
• CPC Class Codes: G02B 6/32 having lens focusing means positioned between opposed fibre ends with lens being an integral part of the single fibre end G02B6/262
• 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 6/3692 with surface micromachining involving etching, e.g. wet or dry etching steps surface micromachining involving subtractive techniques B81C1/00055
• CPC Class Codes: G02B 6/3873 Connectors using guide surfaces for aligning ferrule ends, e.g. tubes, sleeves, V-grooves, rods, pins, balls
• CPC Class Codes: G02B 6/4207 with optical elements reducing the sensitivity to optical feedback anti-reflection devices specially adapted for lasers, see H01S3/0064
• CPC Class Codes: G02B 6/4221 involving a visual detection of the position of the elements, e.g. by using a microscope or a camera
• CPC Class Codes: G02B 6/4224 using visual alignment markings, e.g. index methods
• CPC Class Codes: G02B 6/4225 by a direct measurement of the degree of coupling, e.g. the amount of light power coupled to the fibre or the opto-electronic element
• CPC Class Codes: G02B 6/4226 Positioning means for moving the elements into alignment, e.g. alignment screws, deformation of the mount
• CPC Class Codes: G02B 6/4227 Active alignment methods, e.g. procedures and algorithms
• CPC Class Codes: G02B 6/4228 Passive alignment, i.e. without a detection of the degree of coupling or the position of the elements G02B6/4234 takes precedence
• CPC Class Codes: G02B 6/4231 with intermediate elements, e.g. rods and balls, between the elements
• CPC Class Codes: G02B 6/4232 using the surface tension of fluid solder to align the elements, e.g. solder bump techniques flip-chip mounting techniques in assembly of semiconductor devices H01L24/81
• CPC Class Codes: G02B 6/4236 Fixing or mounting methods of the aligned elements
• CPC Class Codes: G02B 6/4238 Soldering
• CPC Class Codes: G02B 6/4239 Adhesive bonding; Encapsulation with polymer material
• CPC Class Codes: H01L 2224/81141 : Guiding structures both on and outside the body
• CPC Class Codes: Y10T 29/49117 : Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/4913 : Assembling to base an electrical component, e.g., capacitor, etc.
• CPC Class Codes: Y10T 29/49144 : by metal fusion
• CPC Class Codes: Y10T 29/53178 : Chip component

Abstract

An optical device is provided which includes a plurality of optical modules. Each optical module includes an optical component fixedly coupled to a relative reference mount. The relative reference mount is configured to attach to a substrate. A plurality of optical modules mount on the substrate to form the optical device.

Claims

1. A method of making an optical device, comprising:

obtaining a fixed reference mount having a first registration feature and a second registration feature;

obtaining a first optical module comprising;

an optical component;

a relative reference mount including a registration feature configured to align with the first registration feature of the fixed reference mount; and

obtaining a second optical module, comprising;

an optical component; and

a relative reference mount including a registration feature configured to align with the second registration feature of the fixed reference mount;

mounting the first and second optical modules to the fixed reference mount.

2. The method of claim 1 wherein the fixed reference mount comprises a substrate.

3. The method of claim 1 wherein mounting provides substantial alignment between the optical components of the first and second optical modules.

4. The method of claim 1 wherein mounting provides kinematic coupling.

5. The method of claim 1 including providing optical component mounts configured to fixedly couple to the optical components.

6. The method of claim 1 including bonding the optical component to the relative reference mounts.

7. The method of claim 1 including bonding the first and second optical modules to the fixed reference mount.

8. The method of claim 7 wherein bonding uses solder.

9. The method of claim 7 wherein bonding includes applying heat.

10. The method of claim 7 including activating a heater element on the fixed reference mount.

11. The method of claim 10 wherein the heater element comprises a resistive element.

12. The method of claim 10 including providing contact pads on the substrate electrically connected to the heater element.

13. The method of claim 7 including applying radiation.

14. The method of claim 1 wherein at least one optical element has an optical characteristic which varies relative to at least one dimension, and the method including aligning the optical characteristic is aligned with a reference defined relative to a registration feature of the respective relative reference mount.

15. The method of claim 1 including positioning the fixed reference mount registration features to provide alignment between the first and second optical modules.

16. The method of claim 1 wherein the registration features of the relative reference mounts comprise protrusions.

17. The method of claim 16 wherein the first and second registration features of the substrate comprise recesses configured to mate with the protrusions.

18. The method of claim 1 wherein the fixed reference mount comprises silicon.

19. The method of claim 1 wherein the relative reference mounts comprise silicon.

20. The method of claim 1 wherein the fixed reference mount comprises a semiconductor.

21. The method of claim 1 wherein the fixed reference mount comprises a ceramic.

22. A fiber to fiber coupler made in accordance with the method of claim 1.

23. The method of claim 6 wherein the bonding uses solder.

24. The method of claim 6 wherein the bonding maintains a fixed spacial orientation between the optical component mounts and the respective relative reference mounts.

25. The method of claim 6 wherein bonding includes providing a bonding material having a first state in which a position of an optical component can be adjusted and a second state in which the position is fixed.

26. The method of claim 1 wherein the relative reference mounts are substantially planar.

27. The method of claim 7 including providing a bonding pad between the relative reference mounts and the substrate.

28. The method of claim 5 wherein including providing registration features on the optical component mounts configured to register the respective optical components.

29. The method of claim 5 including providing interface surfaces on the optical component mounts and the optical components are flush with the respective interface surfaces.

30. The method of claim 1 including mounting at least one additional optical module.

31. A method of making an optical device, comprising:

obtaining a fixed reference mount having first and second registration features;

obtaining a first optical module comprising;

an optical component;

a relative reference mount having a registration feature configured to align with the first registration feature of the fixed reference mount;

a fixed relative spacial orientation between the optical component and the registration feature of the relative reference mount;

obtaining a second optical module comprising;

an optical component;

a relative reference mount configured to align with the second registration feature of the fixed reference mount;

a fixed relative spacial orientation between the optical component and the registration feature of the relative reference mount; and

placing the first and second optical modules on the fixed reference mount and on respective registration features at fixed spacial orientations relative to each other.

32. The method of claim 31 including providing optical modules include optical component mounts on the optical modules configured to fixedly couple to the optical components.

33. The method of claim 32 including bonding optical component mounts to the relative reference mounts.

34. The method of claim 31 including bonding the first and second optical modules to the fixed reference mount.

35. The method of claim 34 wherein bonding uses solder.

36. The method of claim 34 wherein bonding includes applying heat.

37. The method of claim 34 including activating a heater element configured to heat a bonding material.

38. The method of claim 37 wherein the heater element comprises a resistive element.

39. The method of claim 37 including providing contact pads on the substrate electrically connected to the heater element.

40. The method of claim 34 wherein the bonding includes applying radiation.

41. The method of claim 31 wherein at least one optical element has an optical characteristic which varies relative to at least one dimension, and the method including aligning the optical characteristic aligned with a reference defined relative to a registration feature of the respective relative reference mount.

42. The method of claim 41 including aligning the optical components of the optical modules with each other.

43. The method of claim 31 wherein the registration features of the relative reference mounts comprise protrusions.

44. The method of claim 43 wherein the first and second registration features of the substrate comprise recesses configured to mate with the protrusions.

45. The method of claim 31 wherein the registration features provide substantially kinematic coupling;

and

placing the first and second optical modules on the fixed reference mount at the first and second registration features.

46. The method of claim 31 wherein the fixed reference mount comprises silicon.

47. The method of claim 31 wherein the relative reference mounts comprise silicon.

48. The method of claim 31 wherein the fixed reference mount comprises a semiconductor.

49. The method of claim 31 wherein the fixed reference mount comprises a ceramic.

50. A fiber to fiber coupler made in accordance with the method of claim 31.

51. The method of claim 34 wherein the bonding provides gaps between the first and second optical modules and the fixed reference mount.

52. The method of claim 33 wherein the bonding provides gaps between the optical component mounts and the respective relative reference mounts.

53. The method of claim 33 wherein the bonding uses a bonding material having a first state in which a position of an optical component can be adjusted and a second state in which the position is fixed.

54. The method of claim 31 wherein the relative reference mounts are substantially planar.

55. The method of claim 33 including providing a bonding pad between the relative reference mounts and the fixed reference mount configured to adhere to the bonding material.

56. The method of claim 32 including providing registration features on the optical component mounts for registering the respective optical components.

57. The method of claim 31 wherein the optical component mounts include interface surfaces and the optical components are flush with the respective interface surfaces.

58. The method of claim 31 wherein the fixed reference mount registration features are positioned to provide alignment between the first and second optical modules.

59. The method of claim 31 including placing at least one additional optical module.

60. A method for making an optical device, comprising:

obtaining a fixed reference mount having a first registration feature and a second registration feature;

obtaining a first optical module comprising;

an optical component;

a relative reference mount including a registration feature configured to align with the first registration feature of the fixed reference mount, the registration features providing a substantially kinematic coupling;

obtaining a second optical module, comprising;

an optical component;

obtaining a relative reference mount including a registration feature configured to align with the second registration feature of the fixed reference mount, the registration features providing a substantially kinematic mount; and

kinematically mounting the first and second optical modules to the fixed reference mount with the registration features.

61. The method of claim 60 including fixedly coupling the optical components to the relative reference mounts using optical component mounts.

62. The method of claim 61 including bonding the optical component mounts to the relative reference mounts.

63. The method of claim 62 wherein the bonding uses solder.

64. The method of claim 62 wherein the bonding includes applying heat.

65. The method of claim 62 wherein the bonding includes activating a heater element configured to heat the bonding material.

66. The method of claim 65 wherein the heater element comprises a resistive element.

67. The method of claim 65 including providing contact pads on the fixed reference mount electrically connected to the heater element.

68. The method of claim 60 including aligning the optical components of the optical modules with each other.

69. The method of claim 60 wherein the registration features of the relative reference mounts comprise protrusions.

70. The method of claim 69 wherein the first and second registration features of the fixed reference mount comprise recesses configured to mate with the protrusions.

71. The method of claim 60 including placing at least one additional optical module on the fixed reference mount.

72. The method of claim 60 wherein first and second optical modules are prealigned with respect to first and second registration features, respectively.