Total-internal-reflection fiber optic interface modules and assemblies

• US 8,913,858 B2
• Filed: 03/30/2012
• Issued: 12/16/2014
• Est. Priority Date: 03/30/2012
• Status: Active Grant

• Current Assignee: Corning Optical Communications LLC (Corning Incorporated)
• Original Assignee: Corning Cable Systems LLC (Corning Incorporated)
• Inventors: Charbonneau-Lefort, Mathieu, Ertel, John P., Trott, Gary R.
• Primary Examiner(s): RAHLL, JERRY T
• Application Number:
  US13/436,165
• Publication Number:
  US 20130259431A1
• Time in Patent Office: 991 Days
• Field of Search: None
• US Class Current: 385/33
• CPC Class Codes: G02B 6/4214 the intermediate optical element having redirecting reflective means, e.g. mirrors, prisms for deflecting the radiation from horizontal to down- or upward direction toward a device G02B6/4246 takes precedence
• CPC Class Codes: G02B 6/4224 using visual alignment markings, e.g. index methods
• CPC Class Codes: G02B 6/423 using guiding surfaces for the alignment

Abstract

A fiber optic interface module and assemblies using same are disclosed, wherein the modules have at least one lens that defines a folded optical path through the module body. The module operably supports one or more optical fibers adjacent an end wall. The module includes one or more lenses formed therein for coupling light from one or more light sources to the corresponding one or more optical fibers. The one or more lenses each have a folded optical path formed by total internal reflection within the module body. The one or more lenses each include a lens surface configured to define a back focus that resides within a corresponding one of the optical fibers.

Claims

1. A fiber optic interface module configured to support one or more optical fibers, comprising:

a module body that has front and rear ends, a top surface, a bottom surface and opposing sides, and that is substantially transparent to light having an infrared wavelength;

one or more optical fiber support features formed in the top surface and configured to support respective one or more optical fibers;

a ridge formed in the top surface and having an angled wall that defines a total-internal-reflection (TIR) mirror;

a recess formed in the module body in the bottom surface adjacent the front end and that defines a recess ceiling;

one or more lens surfaces formed on the recess ceiling and having respective folded lens axes that are aligned with the one or more optical fiber support features and the TIR surface, with the one or more lens surfaces defining respective one or more back focus distances F2 from the end wall of the ridge, wherein F2 is greater than zero.

2. The fiber optic interface module according to claim 1, further comprising the one or more lens surfaces being integral with the module body.

3. The fiber optic interface module according to claim 1, wherein the recess ceiling defines a stand-off distance for the one or more lens surfaces, and wherein the stand-off distance is substantially the same as a front focus distance F1.

4. The fiber optic interface module according to claim 1, further comprising the module body having:

a length LZ, wherein 2 mm≦

LZ≦

10 mm;

a width LX, wherein 2 mm≦

LX≦

10 mm; and

a height LY, wherein 1 mm≦

LY≦

4 mm.

5. The optical fiber interface module according to claim 1, wherein the infrared wavelength is in the range of 800 nm to 1,100 nm.

6. The fiber optic interface assembly according to claim 1, further comprising:

a cover configured to mate with and cover the top surface of the module body.

7. The optical fiber interface module according to claim 1, wherein the module body is monolithic.

8. A fiber optic interface assembly, comprising:

the fiber optic interface module according to claim 1;

the one or more optical fibers operably supported in the one or more optical fiber support features, respectively, with the one or more optical fibers having respective ends that interface with the end wall of the ridge; and

one or more active photo-devices operably arranged at respective front focus distances from the one or more lens surfaces so that the one or more active photo-devices are in optical communication with the one or more optical fibers over corresponding one or more folded optical paths.

9. The fiber optic interface assembly according to claim 8:

wherein the one or more active photo-devices include at least one of i) at least one light source and ii) at least one photodetector; and

wherein the one or more folded optical paths include at least one of i) at least one folded source optical path and ii) at least one folded detector optical path.

10. The fiber optic interface assembly according to claim 8, further comprising:

a printed circuit board (PCB) that supports the module;

at least one integrated circuit (IC) chip operably supported by the PCB and that is operably connected to the at least one active photo-device; and

wherein either the PCB or the IC chip operably supports the at least one active photo-device at a focus distance F2 from the at least one lens surface.

11. The fiber optic interface assembly of claim 10, further comprising:

the module body having at least one first passive alignment feature; and

the PCB including at least one second passive alignment feature cooperatively configured with the at least one first passive alignment feature to allow for passive alignment between the module and the PCB.

12. A fiber optic interface assembly for providing optical communication between at least one optical fiber and at least one active photo-device, comprising:

a module having a module body that is transparent to light having an infrared wavelength and that is generally configured as a rectangular cuboid having front and rear ends, a top surface and a bottom surface, with the bottom surface having a recess that is open at the front end and that defines a recess ceiling;

at least one optical fiber support feature formed in the top surface and configured to operably support the at least one optical fiber;

a ridge formed in the top surface and that defines a substantially vertical end wall that terminates the at least one optical fiber support feature, the ridge having an angled wall that defines a total-internal-reflection (TIR) mirror;

the at least one optical fiber supported in the at least one optical fiber support feature and having a central axis and an end that interfaces with the end wall;

at least one lens surface formed on the recess ceiling and having a lens axis that is aligned with the at least one optical fiber support feature and that is folded by the TIR mirror; and

the at least one active photo-device operably disposed adjacent and spaced apart from the at least one lens surface so that the at least one active photo-device is in optical communication with the at least one optical fiber over a corresponding at least one folded optical path that includes a single air-module interface at the lens surface.

13. The fiber optic interface assembly device according to claim 12, wherein the ridge is defined in part by a trench formed in the top surface immediately adjacent the angled wall.

14. The fiber optic interface assembly according to claim 12, further comprising:

a printed circuit board (PCB) that supports the module;

at least one integrated circuit (IC) chip operably supported by the PCB and that is operably connected to the at least one active photo-device; and

wherein either the PCB or the IC chip operably supports the at least one active photo-device at a focus distance F2 from the at least one lens surface.

15. The fiber optic interface assembly according to claim 14, further comprising:

the module body having at least one first passive alignment feature; and

the PCB including at least one second passive alignment feature cooperatively configured with the at least one first passive alignment feature to allow for passive alignment between the module and the PCB.

16. The fiber optic interface assembly according to claim 12, further comprising a window unit operably disposed within the recess and that includes a window and a window unit interior, the window unit interior being configured to contain a medium having an index of refraction higher than air and that covers the at least one active photo-device, and to maintain an air interface adjacent the at least one lens surface.

17. The fiber optic interface assembly according to claim 12, further comprising a window unit operably disposed within the recess and that includes a window and a window unit interior, the window unit interior being configured to contain air and covering the at least one lens surface to maintain an air interface adjacent the lens surface when the at least one active photo-device is covered with a material with an index of refraction higher than air.

18. The fiber optic interface assembly according to claim 17, wherein the widow unit is formed integrally with the module body.

19. The fiber optic interface assembly according to claim 12, wherein the at least one lens surface is aspheric.

20. The fiber optic interface assembly according to claim 12, further comprising:

a cover configured to mate with and cover the top surface of the module body.