Optocoupler Components and Assemblies

Abstract

The present invention describes an optical coupling element including a groove and a light redirecting member. The groove is for receiving and aligning an optical waveguide and includes an open front end and a rear end. The light redirecting member includes an input side for receiving light from the optical waveguide received and supported in the groove and a light redirecting side for changing the direction of the light received from the input side. The groove may include a bottom surface extending between the front end and the rear end of the groove and including a raised bottom surface portion that is raised upward relative to the non-raised bottom surface portion. The non-raised bottom surface portion of the bottom surface may be disposed between the raised bottom surface portion of the bottom surface and the input side of the light redirecting member. The present invention describes an optical coupling assembly including an optical coupling element and an optical waveguide.

Description

[0001] This application is a patent application (International application date June 25, 2019, application number 201980042069.1, invention Divisional application entitled "Optical Coupling Components and Assemblies"). Background Art

[0002] Optical connectors can be used for optical communications in a variety of applications including: telecommunication networks, local area networks, data center links, and internal links in computer devices. Summary of the invention

[0003] In some aspects of the present specification, an optical coupling element is provided, the optical coupling element comprising one or more grooves for receiving one or more optical fibers. At least one groove comprises one or more features that facilitate positioning of the optical fiber in the groove. In some aspects of the present specification, an optical coupling assembly is provided, the optical coupling assembly comprising the optical coupling element and an optical waveguide received and supported in the groove.

[0004] In some aspects of the specification, an optical coupling element is provided, the optical coupling element comprising a groove for receiving and aligning an optical waveguide and comprising an open front end and a rear end. The light redirecting member comprises: an input side for receiving light from the optical waveguide received and supported in the groove; and a light redirecting side for changing the direction of light received from the input side. The groove comprises a bottom surface extending between the front end and the rear end of the groove and comprising a raised bottom surface portion that is raised upwardly relative to a non-raised bottom surface portion, wherein the non-raised bottom surface portion of the bottom surface is disposed between the raised bottom surface portion of the bottom surface and the input side of the light redirecting member.

[0005] In some aspects of the specification, an optical coupling assembly is provided, the optical coupling assembly comprising an optical coupling element and an optical waveguide. The optical coupling element comprises: a groove, the groove is used to receive and align the optical waveguide and includes an open front end, a rear end, and a bottom surface extending between the front end and the rear end of the groove; and a light redirecting member. The light redirecting member includes: an input side, the input side is used to receive light from the optical waveguide received and supported in the groove; and a light redirecting side, the light redirecting side is used to change the direction of the light received from the input side. The optical waveguide is received in and supported by the groove, and has an end face located at or near the input side of the light redirecting member. The optical waveguide includes adjacent first and second segments, wherein the second segment is disposed between the first segment and the input side of the light redirecting member and includes the end surface of the optical waveguide, such that a bottom-most portion of the optical waveguide along the first segment of the optical waveguide rests on and is in physical contact with the bottom surface of the groove, and a bottom-most portion of the optical waveguide along the second segment of the optical waveguide is spaced apart from the bottom surface, thereby defining a gap between the bottom-most portion and the bottom surface.

[0006] In some aspects of the specification, an optical coupling element is provided, the optical coupling element including an attachment area for receiving and permanently attaching to an optical fiber, and a light redirecting member extending from the attachment area. The light redirecting member includes: an input side, the input side for receiving light from the optical fiber disposed at the attachment area; a light redirecting side, the light redirecting side for receiving light from the input side and changing the direction of the light received from the input side; and a groove formed in the attachment area for receiving the optical fiber and extending in a first direction from an entry end to an opposite end near the input side of the light redirecting member. The groove includes a bottom surface and opposite side walls, the opposite side walls extending upward from opposite lateral sides of the bottom surface and defining a width and an open top of the groove; a stop region, the stop region near the input side of the light redirecting member; a centering region, the centering region adjacent to the stop region and opposite to the input side of the light redirecting member; and a support region, the support region located between the entry end and the centering region. The width of the groove in at least a portion of the centering region and in at least a portion of the stop region is smaller than the width of the groove in at least a portion of the support region. The width of the groove in the centering region decreases at a first rate in the first direction, and the width of the groove in at least a portion of the stop region decreases at a second rate in the first direction that is greater than the first rate.

[0007] In some aspects of the specification, an optical coupling element is provided, the optical coupling element comprising a plurality of substantially parallel grooves extending along a first direction and arranged along an orthogonal second direction for receiving and aligning a plurality of optical waveguides and a light redirecting member. The light redirecting member comprises an input side for receiving light from an optical waveguide in a groove among the plurality of grooves and supporting the optical waveguide and a light redirecting side for changing the direction of the light received from the input side. For at least one groove among the plurality of grooves, the groove comprises a bottom surface and opposing sidewalls extending upward from opposing lateral sides of the bottom surface and defining a width of the groove and an open top and an entrance end opposite to an end proximate the input side of the light redirecting member; and a first narrowing region and a second narrowing region spaced apart from each other along the first direction and defining a third region between the first narrowing region and the second narrowing region, such that a minimum width of the groove in each of the first narrowing region and the second narrowing region is less than a minimum width of the groove in the third region.

[0008] In some aspects of the specification, an optical coupling element is provided, the optical coupling element comprising a plurality of substantially parallel grooves extending along a first direction and arranged along an orthogonal second direction for receiving and aligning a plurality of optical waveguides and a light redirecting member. Each groove comprises an open front end, a rear end, a width along the second direction, and a depth along a third direction orthogonal to the first direction and the second direction. The light redirecting member comprises an input side for receiving light from an optical waveguide in a groove in the plurality of grooves and supporting the optical waveguide and a light redirecting side for changing the direction of the light received from the input side. For at least one groove in the plurality of grooves, the groove comprises a first narrowing region disposed between and spaced apart from the front end and the rear end of the groove; a stop region disposed between and spaced apart from the first narrowing region and the rear end of the groove; and a support region disposed between the front end and the first narrowing region of the groove. A rate of change of the width of the groove along the first direction is greater in the stop region than in the first narrowing region, and a minimum width of the groove in the first narrowing region is smaller than a minimum width of the groove in the support region.

[0009] In some aspects of the specification, a method of mounting an optical fiber to an optical coupling element is provided, the optical coupling element including a light redirecting member and a groove extending along a first direction from an entrance end of the groove to an opposite end of the groove proximate an input side of the light redirecting member. The groove has a width along a second direction orthogonal to the first direction and a depth along a third direction orthogonal to the first direction and the second direction. The groove includes a bottom surface extending between the entrance end and the end of the groove and including a raised bottom surface portion that is raised upward relative to a landing portion, wherein the landing portion of the bottom surface is disposed between the raised bottom surface portion of the bottom surface and the input side of the light redirecting member. A landing area of ​​the groove includes the landing portion of the bottom surface and is disposed between the raised bottom surface portion and the end of the groove. The method includes inserting the optical fiber into the groove such that a portion of the landing area of ​​the groove is shaved. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 is a top perspective view of an optical coupling assembly including an optical coupling element and an optical waveguide;

[0011] Figures 2 to 3 is a top perspective view of a portion of an optical coupling assembly;

[0012] Figure 4 is a top view of a portion of an optical coupling assembly;

[0013] Figure 5 is a perspective cutaway view of a portion of an optical coupling assembly;

[0014] Figure 6 is a top perspective view of a portion of an optical coupling assembly;

[0015] Figure 7 is a perspective end cutaway view of a portion of an optical coupling assembly;

[0016] Figure 8 is a top view of a portion of an optical coupling element;

[0017] Fig. 9 is a top view of a portion of the trench;

[0018] Fig.10 is a top perspective view of a portion of an optical coupling assembly;

[0019] Figure 11 to Figure 12 is a cross-sectional view of a portion of an optical coupling assembly;

[0020] FIG. 13A to FIG. 13Cis a cross-sectional view of a portion of an optical coupling assembly in substantially parallel planes;

[0021] Fig.14 is a cross-sectional view of a portion of an optical coupling element;

[0022] Fig.15 is a cross-sectional view of a portion of an optical coupling assembly;

[0023] Figures 16 to 18 is a perspective cutaway view of a portion of an optical coupling assembly;

[0024] Fig.19 is a schematic perspective view of a portion of an optical coupling element having a scraped portion;

[0025] Fig. 20 is a schematic top view of a portion of an optical coupling element having a scraped portion;

[0026] Figure 21 to Figure 26 is a schematic top view of a portion of an optical coupling element;

[0027] Fig. 27 is a schematic cross-sectional view of a portion of an optical coupling assembly;

[0028] Fig.28A is a schematic cross-sectional view of the trench;

[0029] Fig.28B is a schematic cross-sectional view of a trench with an optical fiber seated in the trench;

[0030] Fig.29 is a perspective view of an end portion of an optical fiber inserted into a groove of an optical coupling element;

[0031] Fig.30 is a perspective view of an optical coupling element in which an optical fiber is lowered into a groove of the optical coupling element;

[0032] Fig.31 yes Fig.30 a perspective view of a portion of an optical coupling element;

[0033] Fig.32 After the fiber has been moved into position Fig.30 a perspective view of a portion of an optical coupling element;

[0034] Fig.33 is a perspective view of a plurality of optical fibers positioned in an alignment comb;

[0035] Fig.34A is a top view of an image of a plurality of optical fibers received in a plurality of grooves of an optical coupling element, wherein rear portions of the optical fibers are separated from a raised bottom surface portion of a corresponding groove;

[0036] Fig.34B It is shown Fig.34A A schematic cross-sectional view of the position of an optical fiber relative to a bottom surface portion of a protrusion;

[0037] Fig.35A is a top view of an image of a plurality of optical fibers received in a plurality of grooves of an optical coupling element, wherein leading portions of the optical fibers are separated from a raised bottom surface portion of a corresponding groove;

[0038] Fig.35B It is shown Fig.35A A schematic cross-sectional view of the position of an optical fiber relative to a bottom surface portion of a protrusion;

[0039] Fig.36A is a top view of an image of a plurality of optical fibers received in a plurality of trenches of an optical coupling element, wherein the optical fibers are aligned with raised bottom surface portions of corresponding trenches; and

[0040] Fig.36B It is shown Fig.36A Schematic cross-sectional view of the position of the optical fiber relative to the bottom surface portion of the protrusion. DETAILED DESCRIPTION

[0041] In the following description, reference is made to the accompanying drawings, which form a part of the present invention and in which various embodiments are shown by way of example. The drawings are not necessarily drawn to scale. It should be understood that other embodiments may be conceived and carried out without departing from the scope or essence of the present description. Therefore, the following specific embodiments should not be considered to have a limiting meaning.

[0042] In some embodiments of the optical coupling element described herein, one or more grooves for receiving one or more optical fibers (optical waveguides) are provided, wherein at least one groove includes one or more features that facilitate the positioning of the optical fiber in the groove. For example, the groove may include adjacent centering areas and stop areas, wherein the centering area includes a centering chamfer that helps to position the optical fiber substantially along the centerline of the groove, and wherein the stop area has a relatively rapidly narrowing width that stops the optical fiber when it is pushed forward into the groove. As another example, the groove may include at least one narrowing area. The narrowing area may have a smaller draft angle than the supporting area of ​​the groove, which may produce only a small gap in the narrowing area (e.g., no more than 1 micron or no more than 0.5 micron on each case of the optical fiber). It has been found that the use of two narrowing areas (e.g., each area is close to each end of the groove) allows for improved control of the lateral angle of the optical fiber relative to the desired direction of the optical fiber. As yet another example, the groove may include a bottom surface having a raised portion and a non-raised portion. The raised portion may be, for example, raised by 1 micron to 20 microns relative to the non-raised portion and may provide clearance for rapid burn-in of the laser-cleaved fiber end face and / or for any scraping caused by inserting and lowering the fiber into the groove. The grooves described herein may include centering regions, stop regions, narrowing portions, and any combination of raised and non-raised bottom surface portions.

[0043] In some embodiments, the groove can be formed wider at the top, thereby providing a substantially Y-shaped cross-section (e.g., a Y-shaped groove) that is conducive to capturing the optical waveguide into the groove. Optical coupling units utilizing Y-shaped grooves are described in PCT Publications WO2017 / 066022 (Haase et al.) and 2017 / 066018 (Haase et al.). In some embodiments, the groove has a substantially vertical (e.g., a draft angle of no more than 10 degrees, or no more than 8 degrees, or no more than 6 degrees) lower portion and an upper portion having a greater inclination. The sidewalls of the groove define the width of the groove as the lateral distance across the groove in the lower portion of the groove. The wider upper portion can be conducive to capturing the optical fiber into the groove. The lower portion of the groove can be made slightly wider than the diameter of the optical fiber to provide a gap for initial capture of the optical fiber and allow the optical fiber to slide axially into the centering area and / or stop area of ​​the groove. Alternatively, the lower portion of the groove can be made slightly narrower than the diameter of the optical fiber to provide an interference fit.In some embodiments, grooves other than Y-shaped grooves are used (eg, V-shaped grooves or U-shaped grooves).

[0044] In some embodiments described herein, a method of mounting an optical fiber to an optical coupling element is provided. In some embodiments, the method includes adjusting the position of the optical fiber to reduce or minimize interference fringes observed when the optical fiber is positioned in the groove. It has been found that minimizing the interference fringes can improve the alignment of the optical fiber with the bottom of the groove. In some embodiments, the optical coupling assembly is formed by mounting the optical fiber to the optical coupling element. In some embodiments, the optical fiber is aligned with the groove so that the central ray propagating along the optical fiber is at an angle of less than 1 degree, or less than 0.5 degrees, or less than 0.2 degrees with the bottom of the groove in at least a portion of the optical waveguide near the end face of the optical waveguide.

[0045] Figures 1 to 18 Various views of optical coupling element 1000 or portions of optical coupling element 1000 are provided. Figure 1 1 is a top perspective view of an optical coupling element 1000 that includes an attachment region 10 for receiving and, in some embodiments, permanently attaching to an optical waveguide 20 and a light redirecting member 30. The light redirecting member 30 extends from the attachment region 10 and includes an input side 31 for receiving light from the optical waveguide (optical fiber) 20 disposed at the attachment region 10 (see, e.g., FIG. 1 ). Figure 4 ) and a light redirecting side 32 for changing the direction of light received from the input side 31. In some embodiments, the optical coupling element 1000 includes a plurality of substantially parallel grooves 40 extending along a first direction (x-direction) and arranged along an orthogonal second direction (y-direction) for receiving and aligning the plurality of optical waveguides 20. Figure 1 Also shown is an optical coupling assembly 1500 including the optical coupling element 1000 and the optical waveguide 20. In some embodiments, the optical coupling assembly 1500 includes a plurality of optical waveguides, wherein each of the plurality of optical waveguides is received in and supported by a corresponding groove in the plurality of grooves 40. For example, the substantially parallel grooves may be parallel within 5 degrees.

[0046] In some embodiments, the optical coupling element 1000 and the optical coupling assembly 1500 are adapted to mate with corresponding optical coupling elements and optical coupling assemblies. For example, the optical coupling assembly 1500 can be used to connect ribbon cables together. For example, related optical connectors are described in U.S. Pat. No. 9,482,827 (Haase et al.). The optical coupling element 1000 may include various features, such as a mating tongue 12, to facilitate mating of the optical coupling element 1000 with another optical coupling element 1000.

[0047] In some implementations, the optical coupling element 1000 is a unitary construction. A unitary construction is a one-piece construction that can be made, for example, by molding (eg, injection molding a thermoplastic) or machining.

[0048] Figure 2 4 is a top perspective view of a portion of an optical coupling element 1000 showing a groove 40 having a front end or entrance end 42 and an opposite rear end or terminal end 43. The groove 40 includes a first narrowed region 44 disposed between and spaced apart from the entrance end 42 and the terminal end 43 of the groove 40, and a support region 49 disposed between the entrance end 42 of the groove and the first narrowed region 44. The groove 40 also includes a second narrowed region 80 located at or near the front end 42 of the groove 40. In some embodiments, the optical waveguide 20 includes a polymer buffer 220 surrounding a glass fiber having a glass cladding 120 surrounding a single-mode glass core (not shown). The buffer 220 is removed from the portion of the optical waveguide 20 disposed in the groove 40.

[0049] Figure 3 is a top perspective view of a portion of an optical coupling element 1000, which is used to receive and align the optical waveguide 20 and includes an open front end 42 (see Figure 2 ) and a rear end 31 of the groove 40. In some embodiments, the rear end 31 of the groove 40 is an input side 31 of the light redirecting member 30 for receiving light from the optical waveguide 20 received and supported in the groove 40. The light redirecting member 30 also includes a light redirecting side 32 for changing the direction of light received from the input side 31. The groove 40 includes a bottom surface 50 extending between the front end 42 and the rear end 31 of the groove 40, and includes a raised bottom surface portion 52 that is raised upward relative to the non-raised bottom surface portion 51. The non-raised bottom surface portion 51 of the bottom surface 50 is disposed between the raised bottom surface portion 52 of the bottom surface 50 and the input side 31 of the light redirecting member 30. The groove 40 also includes opposing first and second side walls 60 and 70 that extend upward from opposing lateral sides of the bottom surface 50.

[0050] In some embodiments, the light redirecting member 30 includes one or more light redirecting elements 38. In some embodiments, the light redirecting side 32 of the light redirecting member 30 includes an array of light redirecting elements 38, one light redirecting element for each groove. The light redirecting elements 38 can be one or more of a prism, a lens, and a reflective surface. For example, in some embodiments, the light redirecting member 30 includes one or more lenses 38.

[0051] Figure 41 is a top view of a portion of the optical coupling element 1000. In the illustrated embodiment, the raised portion 52 of the bottom surface 50 has a perimeter 53. In some embodiments, the non-raised bottom surface portion 51 surrounds at least 70%, or at least 90%, or all or substantially all of the perimeter 53 of the raised bottom surface portion 52. In some embodiments, the upper surface of the raised bottom surface portion 52 is substantially planar. In some embodiments, the non-raised bottom surface portion 51 is substantially planar and continuous and includes a first non-raised portion 57 disposed between the raised bottom surface portion 52 and the rear end 31 of the groove 40 and a second non-raised portion 58 disposed on at least one lateral side of the raised bottom surface portion 52. The raised bottom surface portion 52 has an end 79 adjacent to the first portion 57 of the non-raised bottom surface portion 51, the end being disposed between the raised bottom surface portion 52 of the bottom surface 50 and the input side 31 of the light redirecting member 30. In the illustrated embodiment, the second non-raised portion 58 is disposed on each lateral side of the raised bottom surface portion 52. In other embodiments, the second non-raised portion 58 is omitted. Embodiments having alternative bottom surface geometries are further described elsewhere herein.

[0052] Figure 5 is a perspective cross-sectional view of a portion of the optical coupling element 1000. The groove 40 includes a bottom surface having a raised bottom surface portion 52 and a non-raised bottom surface portion 51, and the groove 40 has an open top 41. Figure 6 is a top perspective view of a portion of optical coupling element 1000. Raised portion 52 has an overall length L1′ and a length L1 within and along groove 40, and unraised portion 51 has a length L2 along groove 40. In some embodiments, first length L1 is greater than second length L2. In some embodiments, unraised portion 51 of bottom surface 50 includes a scraped portion on its surface along at least a portion of second length L2 of unraised portion 51 (see, e.g., Fig. 20 For example, when the optical fiber 20 is inserted into the groove 40, a portion of the unraised portion 51 of the bottom surface 50 can be scraped. In addition to or in lieu of a portion of the bottom surface being scraped, one or both sidewalls can also include at least one scraped portion (see, e.g. Fig.19 Scraped portion 183 depicted). In some embodiments, the groove 40 includes at least one scraped portion formed when the optical waveguide 20 scrapes the bottom surface or at least one of the first sidewall or the second sidewall when received in and supported by the groove 40.

[0053] In some embodiments, the raised bottom surface portion 52 is spaced apart from the input side 31 by at least 40 microns, or at least 60 microns, or at least 80 microns. For example, in some embodiments, the non-raised bottom surface portion 51 extends from the raised bottom surface portion 52 to the input side 31 of the light redirecting member 30, and the length L2 is at least 40 microns, or at least 60 microns, or at least 80 microns.

[0054] Figure 7 is a perspective end cross-sectional view of a portion of the optical coupling element 1000. In some embodiments, each groove 40 extends along a first direction (x-direction) and has a width W along a second direction (y-direction) and a depth H along a third direction (z-direction) orthogonal to the first and second directions. In some embodiments, the groove 40 is formed in the attachment area 10 for receiving the optical waveguide 20 and includes a bottom surface 50 and opposing side walls 60, 70 extending upward from opposite lateral sides 54 and 55 of the bottom surface 50 and defining an open top 41 and an input side 31 adjacent to the light redirecting member 30 (see, e.g., FIG. 1 ). Figure 3 ) at the end 43 (see e.g. Figure 2 ) opposite the inlet end 42.

[0055] Figure 8 is a top view of a portion of optical coupling element 1000, and Fig. 9 4 is a top view of a portion of the groove 40. In some embodiments, the optical coupling element 1000 includes a plurality of substantially parallel grooves, and for at least one groove of the plurality of grooves (e.g., the groove 40), the groove 40 includes an open front end 42 disposed at the groove 40 (see, e.g., Figure 2 ) and the rear end 31 and spaced apart from the front end and the rear end; a stop area 46 disposed between the first narrowing area 44 and the rear end 31 of the groove 40 and spaced apart from the first narrowing area and the rear end; and a support area 49 disposed between the front end 42 of the groove 40 and the first narrowing area 44. In some embodiments, for at least one groove 40, the groove 40 further includes a landing area 45 disposed between the first narrowing area 44 and the stop area 46 of the groove 40. In some embodiments, the landing area 45 includes adjacent first and second portions 81, 82 disposed between the first narrowing area 44 and the stop area 46, wherein the first portion 81 extends from the first narrowing area 44 to the second portion 82, and the second portion 82 extends from the first portion 81 to the stop area 46, so that the rate of change of the width of the groove 40 along the first direction is greater in the second portion 82 than in the first portion 81. The second portion 82 can be used as a centering area to center the optical fiber when the optical fiber is positioned in the groove 40.

[0056] In some embodiments, the width of the groove 40 in the first portion 81, the second portion 82, and the stop region 46 varies by a ratio of d1 to d3, and d1<d2<d3. In some embodiments, at least one of the first portion 81 or the second portion 82 of the landing region 45 includes a scraping portion extending along the first direction (see, e.g., Fig. 20 The scraping portion 256 is depicted).

[0057] The rate of change of the width of the groove along the first direction refers to a positive quantity. For example, if the width of the groove is described by a function of a coordinate x along the first direction, the rate of change of the width along the first direction can be expressed as the absolute value of the derivative of the width with respect to x. In some cases, it may be desirable to specify whether the width of the groove increases or decreases in a specified direction. For example, the first direction may be specified such that the groove extends from the entrance end 42 along the first direction to an opposite end 43 near the input side 31 of the light redirecting member 30. In this case, the first direction is the positive x-direction. In some embodiments, the width of the groove 40 in the centering region 82 decreases at a first rate in the first direction, and the width of the groove in at least a portion of the stop region 46 decreases at a second rate in the first direction that is greater than the first rate. The first rate and the second rate are positive quantities.

[0058] It may be useful to describe the geometry of the optical coupling element relative to various planes. For example, in some embodiments, the groove 40 is in a first plane P1 (see, e.g., Fig. 9 ), the rate of change of the width of the groove along the first direction is greater in the stop region 46 than in the first narrowed region 44. As further described elsewhere herein, other useful planes include: a second plane P2 that is substantially perpendicular to the first direction and along a cross section in the support region 49 (e.g., Fig. 13C The cross section depicted in is along the second plane P2); a third plane P3, which is substantially perpendicular to the first direction and along the cross section in the first narrowed region 44 (eg, Fig. 13B The cross section depicted in is along a third plane P3); a plane P4, which is substantially parallel to the first direction and the second direction (e.g., Fig.11 The cross section depicted in is along plane P4); and plane P5, which is substantially perpendicular to the direction (e.g., z-direction) of the light redirected by the light redirecting member (e.g., within 10 degrees) (e.g., Fig.12 The cross section depicted is along plane P5).

[0059] The first plane P1, the plane P4, and the plane P5 may be substantially parallel to each other or may coincide with each other. The first plane P1, the plane P4, and the plane P5 may be independently taken to be at a level such that the plane bisects a portion of the optical fiber disposed on the convex bottom surface portion of the groove or bisects a circle tangent to the bottom surface and the sidewall of the groove, or, for example, the level of the plane may be taken to be H / 2, or the plane may be taken to be flush with the upper surface of the convex bottom surface portion of the bottom surface. FIG. 28A to FIG. 28B 28 is a schematic cross-sectional view of a groove 2840 in a cross section in a support region of the groove substantially perpendicular to a first direction, showing various planes. The groove 2840 includes opposing sidewalls 2860 and 2870 and a bottom surface 2850 including a raised bottom surface portion 2852. The sidewalls 2860 and 2870 have a draft angle with the bottom surface 2850. Fig.28A 2852 and each of the sidewalls 2860 and 2870. Circle 2880 may or may not correspond to an optical fiber disposed in trench 2840. For example, an optical fiber disposed in trench 2840 may have a diameter smaller than circle 2880 such that the optical fiber contacts at most one of the sidewalls 2860 and 2870. Fig.28B Fiber 2820 is shown having a diameter that is smaller than circle 2880. In other embodiments, the diameter of the fiber can be larger than the diameter of circle 2880 so that the fiber is deformed when received by groove 2840. In other embodiments, the diameter of the fiber can be substantially equal to the diameter of circle 2880. Fig.28A As shown in the figure, and plane P11 is Fig.28B . Each of planes P6-P11 is substantially parallel to a plane (xy plane) defined by the first direction and the second direction and / or substantially perpendicular to the third direction (z direction). Sidewalls 2860 and 2870 include a steeper lower portion and a gentler upper portion. Plane P6 passes through the sidewall area between the upper portion and the lower portion. Plane P7 bisects circle 2880. Groove 2840 has a height H, and plane P8 is at a height H / 2 from the non-raised bottom surface portion of bottom surface 2850. Plane P9 passes through a point on the sidewall that is tangent to circle 2880. Plane P10 is flush with raised bottom surface portion 2852. Plane P11 passes through the area of ​​sidewalls 2860 and 2870 closest to optical fiber 2820. In some embodiments, one or more of the illustrated planes may coincide with another illustrated plane. For example, if the diameter of the optical fiber 2820 is equal to the diameter of the circle 2880, the planes P9 and P11 may coincide. The first plane P1, the plane P4, and the plane P5 may be independently taken as any one of the planes P6 to P11, for example.

[0060] In some embodiments, the groove 2840 includes a bottom surface 2850 and opposite sidewalls 2860 and 2870, which extend upward from the opposite lateral sides of the bottom surface 2850 and define the width of the groove and the open top 2841. The width of the groove 2840 can be taken as the lateral opening in the second direction (y direction) in any one of the planes P6 to P11, for example. When comparing the width of the groove in different cross-sections perpendicular to the first direction, the width can be understood to refer to the width in the same plane. For example, if the lateral opening of the groove in any one of the planes P6 to P11, for example, in the center area, decreases at a first rate in the first direction, and the lateral opening of the groove in the same plane in the planes P6 to P11, for example, in at least a portion of the stop area, decreases at a second rate greater than the first rate in the first direction, then the width of the groove in the center area can be described as decreasing at a first rate in the first direction, and the width of the groove in at least a portion of the stop area can be described as decreasing at a second rate greater than the first rate in the first direction.

[0061] Fig.10 is a top perspective view of a portion of optical coupling element 1000, and Fig.11 is a cross-sectional view of a portion of the optical coupling element 1000 in a plane P4 that, in the illustrated embodiment, bisects a portion of the optical fiber 20 disposed on a raised bottom surface portion of the groove 40. In some embodiments, the optical coupling element 1000 includes a plurality of substantially parallel grooves 40 extending along a first direction (x-direction) and arranged along an orthogonal second direction (y-direction) for receiving and supporting a plurality of optical waveguides 20, wherein for at least one groove of the plurality of grooves, the groove includes a first region 82 and a second region 46 disposed in close proximity and sequentially disposed between and spaced apart from a front end 42 and a rear end 31 of the groove, the second region 46 disposed between the first region 82 and the rear end 31 of the groove, such that in a cross-section of the groove in a plane P4 that is substantially parallel to the first and second directions, a rate of change of a lateral opening d (e.g., width) of the groove in the second direction as a function of a distance t from the rear end of the groove is greater in the second region 46 than in the first region 82.

[0062] Fig.12is a cross-sectional view of a portion of the optical coupling element 1000 in plane P5. In some embodiments, the light redirecting member redirects light received from the input side along a first direction to a different second direction (e.g., a z direction), and plane P5 is substantially perpendicular to the second direction. In some embodiments, in a cross-section of the groove 40 in plane P5, at least one of the opposing sidewalls includes a first line segment 61 and a second line segment 62 that intersect each other at a common point 64, wherein a first tangent line 65 and a second tangent line 66 that are tangent to the respective first line segment 61 and the second line segment 62 at the common point 64 form an angle θ1 therebetween. In some embodiments, the angle θ1 is in a range of 95 degrees to 160 degrees. In some embodiments, in a cross-section of the groove 40 in plane P5, at least one of the opposing sidewalls includes a first line segment 161 and a second line segment 163 that intersect each other at a common point 69, wherein a first tangent line 76 and a second tangent line 71 that are tangent to the respective first line segment 161 and the second line segment 163 at the common point 69 form an angle θ2 therebetween. In some embodiments, the angle θ2 is in the range of 120 to 175 degrees. In some embodiments, the angle θ2 is in the range of 95 to θ2 minus 5 degrees. In some embodiments, θ2-θ1 is in the range of 5 to 90 degrees or in the range of 10 to 80 degrees.

[0063] In some embodiments, at least one of the first line segment 61 and the second line segment 62 is curved. In some embodiments, the first line segment 61 is substantially straight and the second line segment 62 is curved.

[0064] In some embodiments, the width of the groove 40 in the stop region 46 decreases sublinearly along the first direction (x direction). In this context, sublinear can be understood to mean that the width of the groove 40 in the stop region 46 decreases more slowly along the first direction than the distance S between the tangent line 66 of the second line segment 62 of the sidewall 60 and the corresponding tangent line 766 tangent to the corresponding second line segment 762 of the sidewall 70.

[0065] FIG. 13A to FIG. 13C 1 and 2 show cross sections of a portion of the optical coupling element 1000 in a plane substantially perpendicular to the first direction in the stop region 46, the first narrowed region 44, and the support region 49. In some embodiments, the first narrowed region 44 and the support region 49 are in respective second planes P2 ( Fig. 13C ) and the third plane P3( Fig. 13B), the rate of change of the width of the groove along the third direction is greater in the support area 49 than in the first narrowed area 44. Alternatively or in addition, the rate of change of the width of the groove along the third direction can be characterized by a draft angle. In some embodiments, each sidewall has a larger draft angle in the support area 49 than in the first narrowed area 44 at the corresponding lateral side of the bottom surface. For example, Fig. 13B The angle α3 depicted in minus 90 degrees is the draft angle of the side wall 60 at the lateral side 54 of the bottom surface in the third plane P3, and Fig. 13C The angle α2 depicted in minus 90 degrees is the draft angle of the sidewall 60 at the lateral side 54 of the bottom surface in the second plane P2. Fig.13A In the cross-section of (in the stop region 46), the draft angle of the sidewall 60 at the lateral side 54 of the bottom surface 50 is 90 degrees minus the illustrated angle β1.

[0066] In some embodiments, the groove includes a first narrowing region 44 and a second narrowing region 80 spaced apart from each other along a first direction and defining a third region 49 therebetween, and the first narrowing region and the second narrowing region may be suitable for supporting an optical waveguide such that each side wall has a larger draft angle in each of the first narrowing region 44 and the second narrowing region 80 at a corresponding lateral side of the bottom surface than in the third region 49.

[0067] Fig.14 and Fig.151 is a cross-sectional view of a portion of the optical coupling element 1000 in a first plane P1, which shows the optical waveguide 20 without being disposed in the groove and the groove with the optical waveguide disposed in the groove. In the illustrated embodiment, the first plane P1 bisects the optical waveguide 20 in at least a portion of the optical fiber disposed in the first narrowing region 44. In some embodiments, the minimum width W1 of the groove 40 in the first narrowing region 44 is less than the minimum width W3 of the groove in the support region 49. In some embodiments, the minimum width W4 of the groove 40 in the second narrowing region 80 is less than the minimum width W3 of the groove in the support region 49. In some embodiments, when an optical waveguide or optical fiber 20 having an average diameter D is received and supported in the groove, the width of the groove in at least a portion of the stop region is less than D. In some embodiments, when an optical waveguide or fiber 20 having an average diameter D is received and supported in the groove 40, in a first cross-section P1 of the groove 40, a minimum width W1 of the groove in the first narrowing region 44 is within about 10% of D (e.g., within a range of D to 1.1D), and a minimum width W2 of the groove in the stop region 46 is less than about 0.8D. In some embodiments, the rate of change of the width of the groove along the first direction is greater in the stop region 46 than in the first narrowing region 44. In some embodiments, a minimum width W3 of the groove in the support region 49 is within about 10% of D (e.g., within a range of D to 1.1D).

[0068] The minimum width W1 of the groove in the first narrowing region 44 may be greater than D (e.g., 1.01D to 1.1D) to allow some clearance between the optical fiber and the sidewall. In some embodiments, the optical fiber received and supported in the groove 40 may have an average diameter that is less than the minimum width of the groove in the first narrowing region 44 but not less than in at least a portion of the stop region 46. In other embodiments, the optical fiber received and supported in the groove 40 may have an average diameter that is approximately equal to the minimum width of the groove in the first narrowing region 44. In some embodiments, when the optical fiber 20 is received and supported in the groove 40, the optical fiber 20 contacts at most one of the sidewalls in the first narrowing region 44. In some embodiments, when the optical fiber 20 is received and supported in the groove 40, the optical fiber 20 contacts both sidewalls in the stop region 46.

[0069] Fig.16 is a perspective cross-sectional view of the optical coupling assembly 1500 taken in a plane substantially perpendicular to the second direction and bisecting the optical waveguide 20. The optical waveguide 20 includes adjacent first and second segments 21, 22, wherein the second segment 22 is disposed between the first segment 21 and the input side 31 of the light redirecting member 30, and includes an end face 26 of the optical waveguide 20. An end 27 of the optical waveguide 20 includes the end face 26. Fig.17 and Fig.18 4 and 5. The bottom surface 50 of the groove 40 includes a raised bottom surface portion 52 raised upward relative to the non-raised bottom surface portion 51, the non-raised bottom surface portion being disposed between a perimeter 53 of the raised bottom surface portion 52 and the input side 31 of the light redirecting member. In some embodiments, the bottom-most portion 23 of the optical waveguide 20 along the first segment 21 of the optical waveguide 20 rests on and is in physical contact with the bottom surface 50 of the groove 40, and the bottom-most portion 24 of the optical waveguide 20 along the second segment 22 of the optical waveguide is spaced from the bottom surface, thereby defining a gap g between the bottom-most portion and the bottom surface. For example, the bottom-most portion 23 along the first segment 21 may rest on and be in physical contact with the raised bottom surface portion 52, and the bottom-most portion 24 along the second segment 22 may be spaced from the non-raised bottom surface portion 51 by a gap g. The gap g can be substantially uniform (e.g., the height of the gap varies by less than 10%), or the first segment 21 of the optical waveguide can have a first diameter and, as further described elsewhere herein, the end face can have a second diameter greater than the first diameter such that the gap g is smaller near the end face 26 than near the periphery 53.

[0070] In some embodiments, an adhesive is used to permanently attach the optical fiber 20 to the attachment area 10. The adhesive can be, for example, an index-matched optical adhesive. In some embodiments, the gap g is at least partially filled with an adhesive 88.

[0071] Fig.19 1 is a schematic perspective view of a portion of an optical coupling element 2000, showing the sidewall 160 of a groove 140 having an end 131, a centering area 182, and a stop area 146. A scraped portion 183 is schematically shown. The optical coupling element 2000 may correspond to the optical coupling element 1000, wherein an optical fiber ( Fig.19 146) produces scraping in the centering area 182 and the stop area 146, which may correspond to the centering area 82 and the stop area 46, respectively. In other embodiments, only a portion of at least one of the sidewalls in one of the centering area 182 or the stop area 146 is scraped. In some embodiments, at least one of the sidewalls in the centering area 182 includes a scraped portion. In some embodiments, each of the sidewalls in the centering area 182 includes a scraped portion.

[0072] Fig. 202 is a schematic top view of a portion of an optical coupling element 3000, which shows a groove 240 having a bottom surface including a raised bottom surface portion 252 and a non-raised bottom surface portion 251. In the illustrated embodiment, the non-raised bottom surface portion 251 includes a first non-raised portion 257 disposed between the raised bottom surface portion 252 and the rear end 231 of the groove 240 and a second non-raised portion 258 disposed on each lateral side of the raised bottom surface portion 252. A scraped portion 256 extending along a first direction (x direction) is shown. The optical coupling element 3000 may correspond to the optical coupling element 1000, in which an optical fiber ( Fig. 20 The scraping portion 256 is produced by (not shown in FIG. 2 ). The groove 240 includes a first narrowing area 244 disposed between and spaced apart from the front end and the rear end 231 of the groove 249, and a stop area 246 disposed between and spaced apart from the first narrowing area 244 and the rear end 231 of the groove. In some embodiments, the groove 240 also includes a landing area 245 disposed between the first narrowing area 244 and the stop area 246 of the groove 240, wherein the landing area 245 includes adjacent first and second portions 281 and 282 disposed between the first narrowing area 244 and the stop area 246. The first portion 281 extends from the first narrowing area 244 to the second portion 282, and the second portion 282 extends from the first portion 281 to the stop area 246. In some embodiments (eg, when the optical waveguide is received in and supported by the groove 240), at least one of the first portion 281 or the second portion 282 of the landing area 245 includes a scraped portion 256 extending along the first direction.

[0073] Figure 21 to Figure 26 Schematic top views of portions of optical coupling elements 4000 - 9000 , each of which may correspond to optical coupling element 1000 or other optical coupling elements described herein, except that the geometry of the corresponding bottom surfaces may vary.

[0074] Fig.21 Schematically showing a first groove 340a and a second groove 340b of an optical coupling element 4000, each of these grooves has a bottom surface 350 including a raised portion 352 and an unraised portion 351. The unraised portion 351 includes a first unraised portion 357 disposed between the raised bottom surface portion 352 and the rear end of the groove and a second unraised portion 358 disposed on each lateral side of the raised bottom surface portion 352. The unraised bottom surface portion 351 surrounds the entire perimeter 353 of the raised bottom surface portion. For example, the second unraised portion 358 may be included to provide more space for an adhesive.

[0075] Fig. 22 Schematically illustrating a first groove 440a and a second groove 440b of an optical coupling element 5000, each of the grooves having a bottom surface 450 including a raised portion 452 and an unraised portion 451. The unraised portion 451 includes a first unraised portion 457 disposed between the raised bottom surface portion 452 and a rear end of the groove and a second unraised portion 458 disposed on each lateral side of the raised bottom surface portion 452. The unraised bottom surface portion 451 surrounds the entire perimeter 453 of the raised bottom surface portion 452. The raised bottom surface portion 452 includes a first raised portion 459 and a second raised portion 463 spaced apart, which are raised upward relative to a portion 474 of the bottom surface 450 disposed between the first and second spaced apart portions 459 and 463. For example, the second unraised portion 458 and the unraised portion 474 may be included to provide more space for an adhesive.

[0076] Fig.23 Schematically showing a first groove 540a and a second groove 540b of an optical coupling element 6000, each of these grooves has a bottom surface 550 including a raised portion 552 and a non-raised portion 551. The non-raised portion 551 includes a first non-raised portion 557 disposed between the raised bottom surface portion 552 and the rear end of the groove and a second non-raised portion 558 disposed on each lateral side of the raised bottom surface portion 552. The non-raised bottom surface portion 551 surrounds most (e.g., at least 70%) of the perimeter 553 of the raised bottom surface portion 552, but not all.

[0077] Fig.24 Schematically illustrating a first groove 640a and a second groove 640b of an optical coupling element 7000, each of the grooves has a bottom surface 650 including a raised portion 652 and a non-raised portion 651. The non-raised portion 651 is disposed between the raised bottom surface portion 652 and the rear end 631 of the groove. In the illustrated embodiment, no portion of the non-raised portion 651 is disposed on any lateral side of the raised bottom portion 652.

[0078] In some embodiments, at least one groove includes adjacent first and second grooves (e.g., grooves 540a and 540b, or grooves 640a and 640b), and the optical coupling element also includes a first raised portion (e.g., first raised portion 594 or first raised portion 694) extending between the entrance ends of each of the first and second grooves, such that a continuous substantially planar top surface (top surface 597 or top surface 697) includes the first raised portion and a top surface portion of each of the raised bottom surface portions of the first and second grooves.

[0079] Fig.25 Schematically showing a first groove 740a and a second groove 740b of an optical coupling element 8000, each of these grooves having a bottom surface 750 including a raised portion 752 and a non-raised portion 751, and each of these grooves including a first narrowing region 742 and a stop region 746. The shortest distance between the raised bottom surface portion 752 and the stop region 746 along the first direction (x direction) is D1, the shortest distance between the first narrowing region 742 and the stop region along the first direction is D2, the shortest distance between the raised bottom surface portion 752 and the first narrowing region 742 along the first direction is D3, and the length of the first narrowing region 742 along the first direction is Lp. It has been found that if D3 is too large, the gap between the portions of the optical fiber above the non-raised surface portion 751 may be too imprecisely controlled for some applications. Thus, in some embodiments, D3 is no more than 2 times the minimum width W3 of the groove in the support region, or no more than W3, or no more than 0.5 W3.

[0080] Fig.26 A first groove 840a and a second groove 840b of an optical coupling element 9000 are shown, each of which has a bottom surface 850 including a raised portion 852 and a non-raised portion 851, and each of which includes a first narrowing region 842 and a stop region 846. The shortest distance between the raised bottom surface portion 852 and the stop region 846 along the first direction (x direction) is D1, the shortest distance between the first narrowing region 842 and the stop region along the first direction is D2, the shortest distance between the raised bottom surface portion 852 and the first narrowing region 842 along the first direction is D3, and the length of the first narrowing region 842 along the first direction is Lp. It has been found that if D3 is too large, the first narrowing portion may not be as effective as is generally desired in centering the optical fiber. Thus, in some embodiments, D3 does not exceed the minimum width W3 of the groove in the support area, or does not exceed 0.5W3, or does not exceed 0.2W3, or does not exceed 0.4D2, or does not exceed 0.2D2, or does not exceed 0.1D2.

[0081] exist Fig.25 In the embodiment shown in , D1>D2, and Fig.26 In the embodiment shown in , D1<D2. In some embodiments, |D2-D1| is less than 2 times the minimum width W3 of the groove in the support area. In some embodiments, 2W3>D1-D2>-0.5W3, or W3>D1-D2>-0.2W3. In some embodiments, 2W3>D1-D2>-0.2D2, or W3>D1-D2>-0.1D2. In some embodiments, the shortest distance D3 along the first direction between the bottom surface portion of the protrusion (e.g., 752 or 852) and the first narrowing region (e.g., 742 or 842) is less than the length Lp of the first narrowing region (e.g., 742 or 842) along the first direction. For example, Figure 25 to Figure 26 D3 depicted in any of may be less than Lp. In some embodiments, the end of the raised bottom surface portion overlaps the length of the first narrowed portion along the first direction, so the shortest distance D3 between the raised bottom surface portion and the first narrowed area along the first direction is zero.

[0082] In some embodiments, the optical waveguide received and supported by the groove of the optical coupling element has been cut by a laser. For example, this can produce a flash-on effect, resulting in an end face having a diameter larger than the average diameter of the optical waveguide. Fig. 27 is a schematic cross-sectional view of a portion of an optical coupling assembly 9500 including an optical waveguide 920 received in and supported by a groove in an optical coupling element 10000, which may correspond to any of the optical coupling elements described elsewhere herein. The groove includes a bottom surface having a raised portion 952 and an unraised portion 951, and includes a centering region 982 and a stop region 946. The optical waveguide 920 includes adjacent first and second segments 921, wherein a bottom-most portion of the optical waveguide 920 along the first segment 921 rests on and is in physical contact with the bottom surface, and a bottom-most portion of the optical waveguide 920 along the second segment 922 is spaced from the bottom surface. In some embodiments, the first segment 921 of the optical waveguide 920 has a first diameter Ds, and the end face 926 has a second diameter Df that is greater than the first diameter Ds. In the illustrated embodiment, the larger diameter Df of the end surface 926 does not cause the end surface 926 to contact the non-raised portion 951.

[0083] Figure 29 to Figure 32A method of mounting an optical fiber 20 to an optical coupling element 1000 is shown. The groove includes a bottom surface 50 extending between an entrance end and a terminal end of the groove and including a raised bottom surface portion 52 that is raised upward relative to a landing portion. A landing area 45 of the groove includes a landing portion of the bottom surface 50 and is disposed between the raised bottom surface portion 52 and the terminal end 43 of the groove 40. The landing portion of the bottom surface 50 is disposed between the raised bottom surface portion 52 of the bottom surface 50 and the input side 31 of the light redirecting member 30 and is or includes a portion of the non-raised bottom surface portion 51 in the landing area 45. In some embodiments, the groove 40 has a first narrowing area 44, and the landing area 45 is disposed between the first narrowing area 44 and the terminal end 43 of the groove 40, wherein a minimum width of the groove in the first narrowing area 44 is less than a width of the groove in an adjacent portion of the landing area 45.

[0084] exist Fig.29 In the embodiment of the present invention, the end of the optical fiber is inserted into the groove so that the end contacts the landing portion of the bottom surface of the groove. The optical fiber 20 is then lowered into the groove until the optical fiber rests on the raised portion of the bottom surface, such as Fig.30 and Fig.31 As shown, Fig.30 is a perspective view of the optical coupling element 1000 and the optical fiber 20, Fig.31 1 is a perspective view of a portion of the optical coupling element 1000 and the optical fiber 20. The optical fiber is then moved along the first direction until the end of the optical fiber contacts the stop region 46, as shown in FIG. Fig.32 shown.

[0085] In some embodiments, the method includes inserting the optical fiber into the groove so that a portion of the landing area of ​​the groove is scraped. In some embodiments, at least one of the step of inserting the end of the optical fiber or the step of lowering the optical fiber includes scraping a portion of the landing portion of the bottom surface. For example, when the end of the optical fiber is inserted into the groove and / or when the optical fiber is lowered into the groove, a portion of the landing portion of the bottom surface of the groove in the landing area may be scraped by the end of the optical fiber. In some embodiments, the step of moving the optical fiber includes scraping a portion of at least one of the opposite first sidewalls and second sidewalls of the groove in the landing area. For example, a portion of at least one of the opposite first sidewalls 60 and second sidewalls 70 of the groove in the landing area 45 may be scraped by the end of the optical fiber, and then the optical fiber moves along the first direction. In some embodiments, a portion of the landing portion of the bottom surface is scraped, and a portion of one or both sidewalls is scraped.

[0086] In some embodiments, inserting the end of the optical fiber into the groove includes positioning the optical fiber such that an axis of the optical fiber proximal to the end of the optical fiber is at an oblique angle to the first direction, such as Fig.29 shown.

[0087] In some embodiments, lowering the optical fiber into the groove forms a gap between the end of the optical fiber and the landing portion (see, e.g., Fig.18 ).

[0088] In some embodiments, the groove is a first groove of a plurality of substantially parallel grooves extending along a first direction and arranged along a second direction when the optical coupling element 1000 includes a plurality of substantially parallel grooves. In some embodiments, the optical fiber is a first optical fiber of a plurality of optical fibers, and the method includes mounting the plurality of optical fibers to the optical coupling element 1000. In some embodiments, the method includes positioning the plurality of optical fibers in an alignment comb. Fig.33 Schematically shown in , which is a perspective view of multiple optical fibers 640 positioned in an alignment comb 677.

[0089] In some embodiments, the method includes: inserting an end of each of the plurality of optical fibers into a corresponding groove in the plurality of grooves so that each end makes contact with a landing portion of the corresponding groove; lowering each optical fiber into the corresponding groove by lowering an alignment comb until the optical fiber rests on a raised portion of a bottom surface of the corresponding groove; and moving each optical fiber along a first direction until the end of the optical fiber contacts a stop area of ​​the corresponding groove. In some embodiments, the method includes: examining interference fringes in the plurality of optical fibers positioned in the plurality of grooves during at least one of the lowering step and the moving step. In some such embodiments, the method also includes: adjusting the position of the alignment comb to reduce any observed interference fringes.

[0090] Fig.34A , Fig.35A and Fig.36A FIG. 3 is a top view of an image of a plurality of optical fibers 3440 received in a plurality of grooves of an optical coupling element 3400, wherein the image is taken using a microscope with a coaxial white light source viewed in the z direction. Interference fringes 3447 are Fig.34A and Fig.35A Visible in. Fig.34B , Fig.35B and Fig.36B 34 is a schematic cross-sectional view showing the relative position of the optical fiber 3440 relative to the raised bottom surface portion 3452. Fig.34A and Fig.34B In the embodiment, the rear portion of the optical fiber 3440 is separated from the raised bottom surface portion 3452, thereby producing Fig.34A The interference fringes 3447 are shown. Fig.35A and Fig.35B In the embodiment, the front portion of the optical fiber 3440 is separated from the raised bottom surface portion 3452, thereby producing Fig.35AThe interference fringes 3447 are shown. Fig.36A and Fig.36B , the optical fiber 3440 is supported by the raised bottom surface portion 3452 over most of its length, thereby producing a long gray region 3448 in which little or essentially no colored interference fringes are observed.

[0091] By appropriately positioning the optical fiber 3440 (e.g., by adjusting the position of the alignment comb), interference fringes can be reduced or substantially eliminated, thereby indicating that the optical fiber is aligned with the raised bottom surface 3452. It has been discovered that adjusting the position of the optical fiber to reduce any observed interference fringes allows the optical fiber to be aligned so that a central ray propagating along the optical fiber makes an angle of less than 1 degree, or less than 0.5 degrees, or less than 0.2 degrees with the bottom of the groove in at least a portion of the optical fiber disposed in the landing portion of the groove. Fig.35B A central ray 3449 is shown propagating along the optical fiber 3440 near the end face of the optical fiber. The central ray 3449 makes an angle δ1 with at least one of the bottom of the groove or the first direction (x direction). In embodiments where the groove has a flat bottom surface portion (e.g., a raised portion or an unraised portion), the angle δ1 with the bottom of the groove is an angle relative to the flat bottom surface portion. In embodiments where the groove is a V-shaped groove, the angle δ1 with the bottom of the groove is an angle relative to the bottom of the V-shaped groove. Fig.35B In the embodiment, the angle δ1 may be greater than 2 degrees, for example. Fig.34A The corresponding central ray 3449 of may be directed downward, for example, at an angle δ1 greater than 2 degrees from the bottom of the trench (δ1 may be understood to be positive for a central ray having an upward or downward component). Fig.36B The corresponding central ray 3449 may have an angle δ1 with the bottom of the groove or the first direction that is less than 1 degree, or less than 0.5 degrees, or less than 0.2 degrees. Fig.36B 34 shows a central ray 3499 in a portion of optical fiber 3440. Central ray 3499 may also be at an angle of less than 1 degree, or less than 0.5 degrees, or less than 0.2 degrees to the bottom of the trench or the first direction.

[0092] Fig.35B Schematically illustrated in FIG. 3 is a central ray 3489 exiting the end face of an optical waveguide 3440 at an angle δ2 to the bottom of the groove or the first direction. δ2 may be understood to be positive for an exiting central ray having an upward component or a downward component. Due to refraction, for example, at the cleaved end face, the exiting central light ray may be at a different angle to the first direction than the central light ray propagating in the optical fiber. In some embodiments, this difference is minimized by using an index matching adhesive between the end face and the input side of the light redirecting element. In some embodiments, the central ray exiting the end face of the optical waveguide is at an angle of less than 1 degree or less than 0.5 degrees to the first direction.

[0093] In some embodiments, the optical waveguide 3440 has a first segment and a second segment (see, e.g., first segment 21 and second segment 22), as further described elsewhere herein. In some embodiments, a central ray propagating along the optical waveguide (e.g., Fig.36B The central light ray 3499 of the optical waveguide is at an angle of less than 1 degree, or less than 0.5 degree, or less than 0.2 degree to the bottom of the groove in at least a portion of the first segment. In some embodiments, the central light ray (e.g., Fig.36B The central light ray 3449 of the optical waveguide is at an angle of less than 1 degree, or less than 0.5 degree, or less than 0.2 degree to the first direction in at least a portion of the second segment. In some embodiments, the central ray (e.g., Fig.36B The outgoing central light ray 3489) makes an angle less than 1 degree or less than 0.5 degrees with the first direction.

[0094] In some embodiments, an optical coupling assembly includes an optical coupling element and a plurality of optical waveguides, the optical coupling element including a plurality of grooves, wherein each of the plurality of optical waveguides is received in and supported by a corresponding groove of the plurality of grooves. In some embodiments, each groove includes a first narrowing region and a second narrowing region spaced apart from each other along a first direction and defining a third region therebetween (e.g., a first narrowing region 44 and a second narrowing region 80 and a third region 49), as further described elsewhere herein. In some embodiments, for each of the plurality of optical waveguides, a central ray propagating along the optical waveguide (e.g., Fig.36B A central light ray 3499) is at an angle of less than 1 degree, or less than 0.5 degrees, or less than 0.2 degrees with the bottom of the groove in at least a portion of the optical waveguide, which contacts the bottom surface of the groove in at least a portion of a third region adjacent to the first narrowed region. In some embodiments, for each optical waveguide and corresponding groove, the bottom surface of the groove includes a raised bottom surface portion that is raised upward relative to an unraised bottom surface portion, wherein the unraised bottom surface portion of the bottom surface is disposed between a raised bottom surface portion of the bottom surface and an input side of the light redirecting member, and the optical waveguide contacts the raised bottom surface portion over at least a continuous portion of the raised bottom surface, the continuous portion including an end of the raised bottom surface portion adjacent to the unraised bottom surface portion. In some embodiments, a central ray (e.g., Fig.36B The central light ray 3499 of the optical waveguide is at an angle of less than 1 degree, or less than 0.5 degree, or less than 0.2 degree to the bottom of the groove in the continuous portion. In some embodiments, for each optical waveguide in the plurality of optical waveguides, the central light ray (e.g., Fig.36B The central light ray 3499) of the optical waveguide is at an angle of less than 1 degree, or less than 0.5 degree, or less than 0.2 degree to the first direction in at least a portion of the optical waveguide disposed between the first narrowed region and the end face of the optical waveguide. In some embodiments, for each optical waveguide in the plurality of optical waveguides, the central light ray (e.g., Fig.36B The departing center ray 3489) makes an angle less than 1 degree or less than 0.5 degrees with the first direction.

[0095] In some embodiments, the optical coupling element includes at least one groove, the at least one groove including a first narrowing region disposed between and spaced apart from a front end and a rear end of the groove; a stop region disposed between and spaced apart from the first narrowing region and the rear end of the groove; and a support region disposed between the front end and the first narrowing region of the groove, as further described elsewhere herein. In some embodiments, the optical waveguide is received in and supported by the at least one groove. In some embodiments, a central ray propagating along the optical waveguide (e.g., Fig.36B The central light ray 3499) of the optical waveguide makes an angle of less than 1 degree, or less than 0.5 degree, or less than 0.2 degree with the bottom of the groove in at least a portion of the optical waveguide, which at least a portion contacts the bottom surface of the groove in at least a portion of the support region adjacent to the first narrowing region. In some embodiments, the central light ray (e.g., Fig.36B A central light ray 3499) of the optical waveguide is at an angle of less than 1 degree, or less than 0.5 degrees, or less than 0.2 degrees to the first direction in at least a portion of the optical waveguide disposed between a first narrowing region and an end face of the optical waveguide. In some embodiments, the groove includes a bottom surface extending between a front end and a rear end of the groove and including a raised bottom surface portion that is raised upward relative to a non-raised bottom surface portion, wherein the non-raised bottom surface portion of the bottom surface is disposed between a raised bottom surface portion of the bottom surface and an input side of the light redirecting member, and the optical waveguide contacts the raised bottom surface portion over at least a continuous portion of the raised bottom surface, wherein the continuous portion includes an end of the raised bottom surface portion that is adjacent to the non-raised bottom surface portion. In some embodiments, a central ray (e.g., Fig.36B The central light ray 3499 of the optical waveguide is at an angle of less than 1 degree, or less than 0.5 degree, or less than 0.2 degree to the bottom of the groove in the continuous portion. In some embodiments, the central ray (e.g., Fig.36B The outgoing central light ray 3489) makes an angle less than 1 degree or less than 0.5 degrees with the first direction.

[0096] The following is a list of exemplary embodiments of the present specification.

[0097] Embodiment A is an optical coupling element, comprising:

[0098] a groove for receiving and supporting the optical waveguide and comprising an open front end and a rear end; and

[0099] A light redirecting member, the light redirecting member comprising:

[0100] an input side for receiving light from an optical waveguide received and supported in the groove; and

[0101] a light redirecting side for changing the direction of light received from the input side, wherein the groove includes a bottom surface extending between the front end and the rear end of the groove and disposed between opposing sidewalls such that when an optical waveguide is received in and supported by the groove, a bottom-most portion of the optical waveguide along a first segment of the optical waveguide rests on and is in physical contact with the bottom surface, and a bottom-most portion of the optical waveguide along a different second segment of the optical waveguide is disposed above the bottom surface, thereby defining a gap between the bottom-most portion and the bottom surface.

[0102] Embodiment B is an optical coupling element, comprising:

[0103] a groove for receiving and supporting the optical waveguide and comprising an open front end and a rear end; and

[0104] A light redirecting member, the light redirecting member comprising:

[0105] an input side for receiving light from an optical waveguide received and supported in the groove; and

[0106] a light redirecting side for changing the direction of light received from the input side, wherein the groove includes a bottom surface extending between the front end and the rear end of the groove and including a raised bottom surface portion raised upward relative to a non-raised bottom surface portion, the non-raised bottom surface portion of the bottom surface being disposed between the raised bottom surface portion of the bottom surface and the input side of the light redirecting member.

[0107] Embodiment C is an optical coupling element according to embodiment B, wherein when the optical waveguide is received in and supported by the groove, a bottom-most portion of the optical waveguide along a first segment of the optical waveguide rests on and makes physical contact with the bottom surface, and a bottom-most portion of the optical waveguide along a different second segment of the optical waveguide is disposed above the bottom surface, thereby defining a gap between the bottom-most portion and the bottom surface.

[0108] Embodiment D is the light coupling element of embodiment B or C, wherein the non-raised portion of the bottom surface extends from the raised portion of the bottom surface to the input side of the light redirecting member.

[0109] Embodiment E is an optical coupling assembly comprising:

[0110] An optical coupling element, the optical coupling element comprising:

[0111] a groove for receiving and supporting an optical waveguide and comprising an open front end, a rear end, and a bottom surface extending between the front end and the rear end of the groove;

[0112] A light redirecting member, the light redirecting member comprising:

[0113] an input side for receiving light from an optical waveguide received and supported in the groove; and

[0114] a light redirecting side for changing the direction of light received from the input side; and

[0115] an optical waveguide received in and supported by the groove, the optical waveguide having an end surface located at or near the input side of the light redirecting member, the optical waveguide comprising adjacent first and second segments, the second segment being disposed between the first segment and the input side of the light redirecting member and comprising the end surface of the optical waveguide, such that a bottom-most portion of the optical waveguide along the first segment of the optical waveguide rests on and is in physical contact with the bottom surface of the groove, and a bottom-most portion of the optical waveguide along the second segment of the optical waveguide is spaced apart from the bottom surface thereby defining a gap between the bottom-most portion and the bottom surface.

[0116] Embodiment F is an optical coupling element, comprising:

[0117] a groove for receiving and supporting the optical waveguide and comprising an open front end and a rear end; and

[0118] A light redirecting member, the light redirecting member comprising:

[0119] an input side for receiving light from an optical waveguide received and supported in the groove; and

[0120] A light redirecting side for changing the direction of light received from the input side, wherein the groove includes a bottom surface extending between the front end and the rear end of the groove and including a raised bottom surface portion raised upward relative to the non-raised bottom surface portion, the non-raised bottom surface portion surrounding at least 70% of the periphery of the raised bottom surface portion.

[0121] Embodiment G is an optical coupling element, comprising:

[0122] an attachment region for receiving an optical fiber and permanently attaching to the optical fiber;

[0123] a light redirecting member extending from the attachment area and comprising:

[0124] an input side for receiving light from an optical waveguide disposed at the attachment area; and

[0125] a light redirecting side for changing the direction of light received from the input side; and

[0126] a groove formed in the attachment area for receiving an optical waveguide and comprising:

[0127] a bottom surface and substantially parallel opposing side walls extending upwardly from opposite lateral sides of the bottom surface and defining an open top and an entrance end opposite an end proximate the input side of the light redirecting member, such that in a cross-section of the groove in a plane substantially parallel to the first direction and the second direction, at least one of the opposing side walls includes a first line segment and a second line segment intersecting each other at a common point, and a first tangent line and a second tangent line tangent to the respective first line segment and the second line segment at the common point form an angle in a range of 95 degrees to 160 degrees therebetween.

[0128] Embodiment H is an optical coupling element according to embodiment G, wherein at least one of the first line segment and the second line segment is curved.

[0129] Embodiment I is an optical coupling element according to embodiment G or H, wherein the first line segment is substantially straight and the second line segment 62 is curved.

[0130] Embodiment J is an optical coupling element, comprising:

[0131] an attachment region for receiving the optical waveguide and permanently attaching to the optical waveguide;

[0132] a light redirecting member extending from the attachment area and comprising:

[0133] an input side for receiving light from an optical waveguide disposed at the attachment area; and

[0134] a light redirecting side for changing the direction of light received from the input side; and

[0135] A groove is formed in the attachment area for receiving an optical waveguide and includes a bottom surface (50) extending between an entrance end of the groove and an opposite end of the groove proximate the input side of the light redirecting member, the bottom surface including a raised portion, thereby leaving an unraised portion between the raised portion and the input side, the raised portion and the unraised portion having respective first and second lengths along the groove, the first length being greater than the second length, the unraised portion of the bottom surface including a scraped portion on its surface along at least a portion of the second length of the unraised portion.

[0136] Embodiment K is an optical coupling element, comprising:

[0137] a plurality of substantially parallel grooves extending along a first direction and arranged along an orthogonal second direction for receiving and supporting a plurality of optical waveguides; and

[0138] A light redirecting member, the light redirecting member comprising:

[0139] an input side for receiving light from an optical waveguide received and supported in a groove among the plurality of grooves; and

[0140] a light redirecting side for changing the direction of light received from the input side, wherein for at least one groove of the plurality of grooves, the groove comprises:

[0141] a bottom surface and opposed side walls extending upwardly from opposed lateral sides of the bottom surface and defining an open top and an entrance end opposite an end proximate the input side of the light redirecting member;

[0142] A first narrowing region and a second narrowing region, the first narrowing region and the second narrowing region are spaced apart from each other along the first direction and define a third region between the first narrowing region and the second narrowing region, so that in cross-sections of the first narrowing region, the second narrowing region and the third region in corresponding first planes, second planes and third planes substantially perpendicular to the first direction, each side wall of the groove includes a first average draft angle, a second average draft angle and a third average draft angle in the corresponding first planes, the second planes and the third planes, and the third average draft angle is greater than each of the first average draft angle and the second average draft angle.

[0143] Embodiment L is an optical coupling element, comprising:

[0144] a plurality of substantially parallel grooves extending along a first direction and arranged along an orthogonal second direction for receiving and supporting a plurality of optical waveguides, each groove comprising an open front end and a rear end; and

[0145] A light redirecting member, the light redirecting member comprising:

[0146] an input side for receiving light from an optical waveguide received and supported in a groove among the plurality of grooves; and

[0147] A light redirecting side, the light redirecting side being used to change the direction of light received from the input side, wherein for at least one groove of the plurality of grooves, the groove includes a raised bottom surface portion, the raised bottom surface portion is raised upward relative to a substantially planar continuous non-raised bottom surface portion substantially parallel to the first direction and the second direction, the substantially planar continuous non-raised bottom surface portion including a first non-raised portion disposed between the raised bottom surface portion and the rear end of the groove and a second non-raised portion disposed on at least one lateral side of the raised bottom surface portion.

[0148] Embodiment M is an optical coupling element, comprising:

[0149] a plurality of substantially parallel grooves extending along a first direction and arranged along an orthogonal second direction for receiving and supporting a plurality of optical waveguides, each groove being disposed between opposing sidewalls and including an open front end and a rear end; and

[0150] A light redirecting member, the light redirecting member comprising:

[0151] an input side for receiving light from an optical waveguide disposed in a groove among the plurality of grooves; and

[0152] a light redirecting side for changing the direction of light received from the input side, wherein for at least one groove among the plurality of grooves, the groove includes a first region and a second region arranged in close sequence, the first region and the second region being disposed between and spaced apart from the front end and the rear end of the groove, the second region being disposed between the first region and the rear end of the groove, so that in a cross section of the groove in a plane substantially parallel to the first direction and the second direction, a rate of change of a lateral opening of the groove as a function of a distance from the rear end of the groove in the second direction is greater in the second region than in the first region, wherein at least one of the opposite side walls of the groove includes a scraped portion along the first direction along at least a portion of the side wall in the first region.

[0153] Embodiment N is an optical coupling element according to embodiment M, wherein the scraped portion extends into the second region.

[0154] Embodiment O is an optical coupling element, comprising:

[0155] a plurality of substantially parallel grooves extending along a first direction and arranged along an orthogonal second direction for receiving and supporting a plurality of optical waveguides, each groove comprising an open front end, a rear end, a width along the second direction, and a depth along a third direction orthogonal to the first direction and the second direction; and

[0156] A light redirecting member, the light redirecting member comprising:

[0157] an input side for receiving light from an optical waveguide received and supported in a groove among the plurality of grooves; and

[0158] a light redirecting side for changing the direction of light received from the input side, wherein for at least one groove of the plurality of grooves, the groove comprises:

[0159] a first narrowed region disposed between and spaced apart from the front end and the rear end of the groove;

[0160] a stop region disposed between and spaced apart from the first narrowed region and the rear end of the groove; and

[0161] A support area, the support area is arranged between the front end of the groove and the first narrowing area, so that:

[0162] In a first cross-section of the groove in a first plane substantially perpendicular to the third direction, a rate of change of the width of the groove along the first direction is greater in the stop region than in the first narrowing region; and

[0163] In cross-sections of the first narrowing region and the supporting region in respective second and third planes substantially perpendicular to the first direction, a rate of change of the groove width along the third direction is greater in the supporting region than in the first narrowing region.

[0164] Embodiment P is an optical coupling element according to embodiment O, such that when an optical waveguide having an average diameter D is received and supported in the groove, in the first cross-section of the groove, the minimum width of the groove in the first narrowing region is within about 10% of D, and the minimum width of the groove in the stop region is less than about 0.8D.

[0165] Embodiment Q is an optical coupling element according to embodiment O or P, wherein for the at least one groove, the groove also includes a second narrowing region at or near the front end of the groove, so that the support region of the groove is arranged between the first narrowing region and the second narrowing region of the groove, and in the first cross-section of the groove, the minimum width of the groove in the support region is greater than the minimum width of the groove in each of the first narrowing region and the second narrowing region.

[0166] Embodiment R is an optical coupling element according to embodiment O, P or Q, wherein for the at least one groove, the groove also includes a landing area, and the landing area is arranged between the first narrowing area and the stop area of ​​the groove.

[0167] Embodiment S is an optical coupling element according to embodiment R, wherein the landing area includes a first portion and a second portion adjacent to each other and arranged between the first narrowing area and the stop area, the first portion extends from the first narrowing area to the second portion, and the second portion extends from the first portion to the stop area, so that in the first cross-section in the first plane of the groove, the rate of change of the width of the groove along the first direction is greater in the second portion than in the first portion.

[0168] Implementation T is an optical coupling element according to implementation S, wherein in the first cross-section in the first plane of the groove, the rates of change of the width of the groove in the first portion, the second portion and the stop region are d1 to d3, respectively, and d1<d2<d3.

[0169] Embodiment U is an optical coupling element according to embodiment S or T, wherein at least one of the first portion and the second portion of the landing area includes a scraped portion extending along the first direction.

[0170] Embodiment 1 is an optical coupling element, comprising:

[0171] a groove for receiving and aligning the optical waveguide and comprising an open front end and a rear end; and

[0172] A light redirecting member, the light redirecting member comprising:

[0173] an input side for receiving light from an optical waveguide received and supported in the groove; and

[0174] a light redirecting side for changing the direction of light received from the input side, wherein the groove includes a bottom surface extending between the front end and the rear end of the groove and including a raised bottom surface portion raised upward relative to a non-raised bottom surface portion, the non-raised bottom surface portion of the bottom surface being disposed between the raised bottom surface portion of the bottom surface and the input side of the light redirecting member.

[0175] Embodiment 2 is an optical coupling element according to embodiment 1, wherein when the optical waveguide is received in and supported by the groove, the bottom-most portion of the optical waveguide along a first segment of the optical waveguide rests on and makes physical contact with the bottom surface, and the bottom-most portion of the optical waveguide along a different second segment of the optical waveguide is disposed above the bottom surface, thereby defining a gap between the bottom-most portion and the bottom surface.

[0176] Embodiment 3 is the light coupling element according to embodiment 1 or 2, wherein the non-raised portion of the bottom surface extends from the raised portion of the bottom surface to the input side of the light redirecting member.

[0177] Embodiment 4 is an optical coupling element according to any one of embodiments 1 to 3, wherein the raised bottom surface portion is spaced apart from the input side by at least 40 microns.

[0178] Embodiment 5 is an optical coupling element according to any one of embodiments 1 to 4, wherein the non-raised bottom surface portion includes a scraped portion.

[0179] Embodiment 6 is an optical coupling element according to any one of embodiments 1 to 5, wherein the raised bottom surface portion includes a first raised portion and a second raised portion spaced apart, and the first raised portion and the second raised portion are raised upward relative to a portion of the bottom surface disposed between the first raised portion and the second raised portion spaced apart.

[0180] Embodiment 7 is an optical coupling element according to any one of embodiments 1 to 6, wherein the upper surface of the raised bottom surface portion is substantially planar.

[0181] Embodiment 8 is an optical coupling element according to any one of embodiments 1 to 7, wherein the light redirecting member includes one or more lenses.

[0182] Embodiment 9 is an optical coupling element according to any one of embodiments 1 to 8, wherein the optical coupling element is an integral structure.

[0183] Embodiment 10 is an optical coupling element according to any one of embodiments 1 to 9, wherein the groove is the first groove among a plurality of substantially parallel grooves extending along a first direction and arranged along an orthogonal second direction for receiving and aligning a plurality of optical waveguides.

[0184] Embodiment 11 is the optical coupling element of any one of embodiments 1 to 10, wherein the groove extends along the first direction and comprises:

[0185] a first narrowed region disposed between and spaced apart from the front end and the rear end of the groove; and

[0186] A supporting area is provided between the front end of the groove and the first narrowing area, and a minimum width of the groove in the first narrowing area is smaller than a minimum width of the groove in the supporting area.

[0187] Embodiment 12 is an optical coupling element according to embodiment 11, wherein the shortest distance along the first direction between the raised bottom surface portion and the first narrowed region is smaller than the length of the first narrowed region along the first direction.

[0188] Embodiment 13 is an optical coupling element according to embodiment 11 or 12, wherein the groove also includes a stop area arranged between the first narrowing area and the rear end of the groove and spaced apart from the first narrowing area and the rear end, and the minimum width of the groove in the stop area is smaller than the minimum width of the groove in the first narrowing area.

[0189] Embodiment 14 is an optical coupling element as described in embodiment 13, wherein the shortest distance along the first direction between the bottom surface portion of the protrusion and the stop area is D1, the shortest distance along the first direction between the first narrowing area and the stop area is D2, and |D2-D1| is less than 2 times the minimum width W3 of the groove in the support area.

[0190] Embodiment 15 is an optical coupling element according to embodiment 14, wherein 2W3>D1-D2>-0.5W3.

[0191] Embodiment 16 is an optical coupling element according to embodiment 14, wherein W3>D1-D2>-0.2W3.

[0192] Embodiment 17 is an optical coupling element according to embodiment 14, wherein 2W3>D1-D2>-0.2D2.

[0193] Embodiment 18 is an optical coupling element according to embodiment 14, wherein W3>D1-D2>-0.1D2.

[0194] Embodiment 19 is an optical coupling component, comprising:

[0195] An optical coupling element, the optical coupling element comprising:

[0196] a groove for receiving and aligning an optical waveguide and comprising an open front end, a rear end, and a bottom surface extending between the front end and the rear end of the groove;

[0197] A light redirecting member, the light redirecting member comprising:

[0198] an input side for receiving light from an optical waveguide received and supported in the groove; and

[0199] a light redirecting side for changing the direction of light received from the input side; and

[0200] an optical waveguide received in and supported by the groove, the optical waveguide having an end surface located at or near the input side of the light redirecting member, the optical waveguide comprising adjacent first and second segments, the second segment being disposed between the first segment and the input side of the light redirecting member and comprising the end surface of the optical waveguide, such that a bottom-most portion of the optical waveguide along the first segment of the optical waveguide rests on and is in physical contact with the bottom surface of the groove, and a bottom-most portion of the optical waveguide along the second segment of the optical waveguide is spaced apart from the bottom surface thereby defining a gap between the bottom-most portion and the bottom surface.

[0201] Embodiment 20 is an optical coupling component according to embodiment 19, wherein the first segment of the optical waveguide has a first diameter and the end face has a second diameter greater than the first diameter.

[0202] Embodiment 21 is an optical coupling assembly according to embodiment 19 or 20, wherein the gap is at least partially filled with adhesive.

[0203] Embodiment 22 is an optical coupling component described in any one of embodiments 19 to 21, wherein the bottom surface includes a raised bottom surface portion that is raised upward relative to a non-raised bottom surface portion, and the non-raised bottom surface portion of the bottom surface is arranged between the raised bottom surface portion of the bottom surface and the input side of the light redirecting member.

[0204] Embodiment 23 is an optical coupling component described in any of embodiments 19 to 22, wherein the groove further includes opposing first and second side walls extending upward from opposing lateral sides of the bottom surface.

[0205] Embodiment 24 is the optical coupling component of embodiment 23, wherein the groove includes at least one scraped portion, and the at least one scraped portion is formed when the optical waveguide scrapes the bottom surface or at least one of the first sidewall or the second sidewall when being received in the groove and supported by the groove.

[0206] Embodiment 25 is an optical coupling component according to any one of embodiments 19 to 24, so that the central ray propagating along the optical waveguide makes an angle of less than 1 degree, or less than 0.5 degrees, or less than 0.2 degrees with the bottom of the groove in at least a portion of the first segment.

[0207] Embodiment 26 is an optical coupling component according to any one of embodiments 19 to 25, so that the central ray propagating along the optical waveguide makes an angle less than 1 degree, or less than 0.5 degrees, or less than 0.2 degrees with the first direction in at least a portion of the second segment.

[0208] Embodiment 27 is an optical coupling component according to any one of embodiments 19 to 26, wherein a central ray leaving the end face of the optical waveguide makes an angle of less than 1 degree or less than 0.5 degrees with the first direction.

[0209] Embodiment 28 is an optical coupling component according to any one of embodiments 19 to 27, wherein the groove is a first groove among a plurality of substantially parallel grooves, the plurality of substantially parallel grooves extending along a first direction and arranged along an orthogonal second direction, and the optical waveguide is a first optical waveguide among a plurality of optical waveguides, each optical waveguide of the plurality of optical waveguides being received in and supported by a corresponding groove among the plurality of grooves.

[0210] Embodiment 29 is the optical coupling element of any one of embodiments 1 to 18 or the optical coupling assembly of any one of embodiments 19 to 28, wherein the groove further comprises:

[0211] a stop region proximate the input side of the light redirecting member;

[0212] a centering region adjacent the stop region and opposite the input side of the light redirecting member; and

[0213] a support area, the support area being located between the front end and the centering area, the width of the groove in at least a portion of the centering area and in at least a portion of the stop area being smaller than the width of the groove in at least a portion of the support area,

[0214] The width of the groove in the intermediate region decreases at a first rate from the front end to the rear end in a first direction, and the width of the groove in at least a portion of the stop region decreases at a second rate in the first direction that is greater than the first rate.

[0215] Embodiment 30 is an optical coupling element according to any one of embodiments 1 to 18 or an optical coupling component according to any one of embodiments 19 to 28, wherein the groove includes a first narrowing region and a second narrowing region, the first narrowing region and the second narrowing region are spaced apart from each other along a first direction from the front end to the rear end and define a third region between the first narrowing region and the second narrowing region, so that the minimum width of the groove in each of the first narrowing region and the second narrowing region is smaller than the minimum width of the groove in the third region.

[0216] Embodiment 31 is an optical coupling element, comprising:

[0217] an attachment region for receiving an optical fiber and permanently attaching to the optical fiber;

[0218] a light redirecting member extending from the attachment area and comprising:

[0219] an input side for receiving light from an optical fiber disposed at the attachment area;

[0220] a light redirecting side for receiving light from the input side and changing the direction of the light received from the input side; and

[0221] a groove formed in the attachment region for receiving an optical fiber and extending in a first direction from an entrance end to an opposite end proximate the input side of the light redirecting member, the groove comprising:

[0222] a bottom surface and opposed side walls extending upwardly from opposed lateral sides of the bottom surface and defining a width and an open top of the groove;

[0223] a stop region proximate the input side of the light redirecting member;

[0224] a centering region adjacent the stop region and opposite the input side of the light redirecting member; and

[0225] a support area between the inlet end and the centering area, the width of the groove in at least a portion of the centering area and in at least a portion of the stop area being smaller than the width of the groove in at least a portion of the support area,

[0226] The width of the groove in the intermediate region decreases at a first rate in the first direction, and the width of the groove in at least a portion of the stop region decreases at a second rate in the first direction that is greater than the first rate.

[0227] Embodiment 32 is an optical coupling element according to embodiment 31, such that when an optical fiber having an average diameter D is received and supported in the groove, the width of the groove in at least a portion of the stop region is less than D.

[0228] Embodiment 33 is an optical coupling element according to embodiment 31, such that when an optical fiber having an average diameter D is received and supported in the groove, the width of the groove in at least a portion of the centering area and in at least a portion of the stop area is less than D.

[0229] Embodiment 34 is an optical coupling element according to any one of embodiments 31 to 33, such that when an optical fiber having an average diameter D is received and supported in the groove, the minimum width of the groove in the supporting area is in the range of D to 1.1D, and the minimum width of the groove in the stop area is less than about 0.8D.

[0230] Embodiment 35 is an optical coupling element according to any one of embodiments 31 to 34, wherein the minimum width of the groove in the stop region is smaller than the minimum width of the groove in the center region, and the minimum width of the groove in the center region is smaller than the minimum width of the groove in the support region.

[0231] Embodiment 36 is an optical coupling element according to any one of embodiments 31 to 35, wherein the width of the groove in the stop region decreases sublinearly along the first direction.

[0232] Embodiment 37 is an optical coupling element according to any one of embodiments 31 to 36, wherein at least one of the sidewalls in the central region includes a scraped portion.

[0233] Embodiment 38 is an optical coupling element according to any one of embodiments 31 to 37, wherein each of the sidewalls in the central region includes a scraped portion.

[0234] Embodiment 39 is an optical coupling element according to any one of embodiments 31 to 38, wherein the groove also includes a first narrowing region arranged between the supporting region and the central region, and the minimum width of the groove in the first narrowing region is smaller than the minimum width of the groove in the supporting region.

[0235] Embodiment 40 is an optical coupling element according to embodiment 39, wherein when the optical fiber is received and supported in the groove, the optical fiber contacts at most one of the side walls in the first narrowing region.

[0236] Embodiment 41 is an optical coupling element according to any one of embodiments 31 to 40, wherein when the optical fiber is received and supported in the groove, the optical fiber contacts two of the side walls in the stop area.

[0237] Embodiment 42 is an optical coupling element, comprising:

[0238] a plurality of substantially parallel grooves extending along a first direction and arranged along an orthogonal second direction for receiving and aligning a plurality of optical waveguides; and

[0239] A light redirecting member, the light redirecting member comprising:

[0240] an input side for receiving light from an optical waveguide received and supported in a groove among the plurality of grooves; and

[0241] a light redirecting side for changing the direction of light received from the input side, wherein for at least one groove of the plurality of grooves, the groove comprises:

[0242] a bottom surface and opposed side walls extending upwardly from opposed lateral sides of the bottom surface and defining a width and an open top of the groove and an entrance end opposite an end proximate the input side of the light redirecting member;

[0243] A first narrowing region and a second narrowing region, wherein the first narrowing region and the second narrowing region are spaced apart from each other along the first direction and define a third region between the first narrowing region and the second narrowing region, so that the minimum width of the groove in each of the first narrowing region and the second narrowing region is smaller than the minimum width of the groove in the third region.

[0244] Embodiment 43 is an optical coupling element according to embodiment 42, wherein each side wall has a larger draft angle at the corresponding lateral side of the bottom surface in each of the first narrowing region and the second narrowing region than in the third region.

[0245] Embodiment 44 is an optical coupling element according to embodiment 42 or 43, wherein for at least one of the plurality of grooves, the bottom surface includes a raised bottom surface portion that is raised upward relative to a non-raised bottom surface portion.

[0246] Embodiment 45 is an optical coupling element according to embodiment 44, wherein the non-raised bottom surface portion of the bottom surface is disposed between the raised bottom surface portion of the bottom surface and the input side of the light redirecting member.

[0247] Embodiment 46 is an optical coupling element according to embodiment 44, wherein the unraised bottom surface portion includes a first unraised portion arranged between the raised bottom surface portion and the input side of the light redirecting member and a second unraised portion arranged on at least one lateral side of the raised bottom surface portion.

[0248] Embodiment 47 is an optical coupling element according to embodiment 46, wherein the non-raised bottom surface portion surrounds at least 70% of the perimeter of the raised bottom surface portion.

[0249] Embodiment 48 is an optical coupling element according to any one of embodiments 44 to 47, wherein the at least one groove includes adjacent first and second grooves, and the optical coupling element also includes a first raised portion extending between the entrance ends of each of the first groove and the second groove, so that a continuous substantially planar top surface includes a top surface portion of the first raised portion and a top surface portion of each of the raised bottom surface portions of the first groove and the second groove.

[0250] Embodiment 49 is an optical coupling component, which includes an optical coupling element according to any one of embodiments 42 to 48 and a plurality of optical waveguides, each of the plurality of optical waveguides being received in and supported by a corresponding groove among the plurality of grooves.

[0251] Embodiment 50 is an optical coupling component according to embodiment 49, wherein for each optical waveguide of the plurality of optical waveguides, a central ray propagating along the optical waveguide makes an angle of less than 1 degree, or less than 0.5 degrees, or less than 0.2 degrees with the bottom of the groove in at least a portion of the optical waveguide, and at least a portion of the optical waveguide contacts the bottom surface of the groove in at least a portion of the third region adjacent to the first narrowing region.

[0252] Embodiment 51 is an optical coupling component according to embodiment 49 or 50, wherein for each optical waveguide and corresponding groove, the bottom surface of the groove includes a raised bottom surface portion that is raised upward relative to the non-raised bottom surface portion, the non-raised bottom surface portion of the bottom surface is arranged between the raised bottom surface portion of the bottom surface and the input side of the light redirecting member, the optical waveguide contacts the raised bottom surface portion over at least a continuous portion of the raised bottom surface, the continuous portion includes an end portion of the raised bottom surface portion adjacent to the non-raised bottom surface portion, wherein a central ray propagating along the optical waveguide in the continuous portion makes an angle with the bottom of the groove that is less than 1 degree, or less than 0.5 degrees, or less than 0.2 degrees.

[0253] Embodiment 52 is an optical coupling component according to any one of embodiments 49 to 51, wherein for each optical waveguide of the plurality of optical waveguides, a central ray propagating along the optical waveguide makes an angle of less than 1 degree, or less than 0.5 degrees, or less than 0.2 degrees with the first direction in at least a portion of the optical waveguide disposed between the first narrowing region and an end face of the optical waveguide.

[0254] Embodiment 53 is an optical coupling component according to any one of embodiments 49 to 52, wherein for each optical waveguide of the plurality of optical waveguides, a central ray leaving an end face of the optical waveguide makes an angle of less than 1 degree or less than 0.5 degrees with the first direction.

[0255] Embodiment 54 is an optical coupling component according to any one of embodiments 49 to 53, wherein at least one scraped portion is formed in at least one of the plurality of grooves when at least one of the first portion and the second portion of the landing area is scraped when the corresponding optical waveguide is received in and supported by the at least one groove.

[0256] Embodiment 55 is an optical coupling element, comprising:

[0257] a plurality of substantially parallel grooves extending along a first direction and arranged along an orthogonal second direction for receiving and aligning a plurality of optical waveguides, each groove comprising an open front end, a rear end, a width along the second direction, and a depth along a third direction orthogonal to the first direction and the second direction; and

[0258] A light redirecting member, the light redirecting member comprising:

[0259] an input side for receiving light from an optical waveguide received and supported in a groove among the plurality of grooves; and

[0260] a light redirecting side for changing the direction of light received from the input side, wherein for at least one groove of the plurality of grooves, the groove comprises:

[0261] a first narrowed region disposed between and spaced apart from the front end and the rear end of the groove;

[0262] a stop region disposed between and spaced apart from the first narrowed region and the rear end of the groove; and

[0263] A support area, the support area is arranged between the front end of the groove and the first narrowing area, so that:

[0264] A rate of change of the width of the groove along the first direction is greater in the stop region than in the first narrowing region, and a minimum width of the groove in the first narrowing region is smaller than a minimum width of the groove in the support region.

[0265] Embodiment 56 is an optical coupling element according to embodiment 55, wherein for the at least one groove, the groove also includes a bottom surface and relative side walls extending upward from relative lateral sides of the bottom surface, and each side wall has a larger draft angle in the support area at the corresponding lateral side of the bottom surface than in the first narrowing area.

[0266] Embodiment 57 is an optical coupling element according to embodiment 55 or 56, such that when an optical waveguide having an average diameter D is received and supported in the groove, the minimum width of the groove in the first narrowing region is in the range of D to 1.1D, and the minimum width of the groove in the stop region is less than about 0.8D.

[0267] Embodiment 58 is an optical coupling element according to embodiment 57, wherein the minimum width of the groove in the first narrowed region is greater than D.

[0268] Embodiment 59 is an optical coupling element according to any one of embodiments 55 to 58, wherein for the at least one groove, the groove also includes a second narrowing region, the second narrowing region has a minimum width and is arranged at or near the front end of the groove, so that the support region of the groove is arranged between the first narrowing region and the second narrowing region of the groove, and the minimum width of the groove in the support region is greater than the minimum width of the groove in each of the first narrowing region and the second narrowing region.

[0269] Embodiment 60 is an optical coupling element according to any one of embodiments 55 to 60, wherein for the at least one groove, the groove also includes a landing area, and the landing area is arranged between the first narrowing area and the stop area of ​​the groove.

[0270] Embodiment 61 is an optical coupling element according to embodiment 60, wherein the landing area includes a first portion and a second portion adjacent to each other and arranged between the first narrowing area and the stop area, the first portion extends from the first narrowing area to the second portion, and the second portion extends from the first portion to the stop area, so that the rate of change of the width of the groove along the first direction is greater in the second portion than in the first portion.

[0271] Embodiment 62 is an optical coupling element according to embodiment 61, wherein the rates of change of the width of the groove in the first portion, the second portion, and the stop region are d1 to d3, respectively, and d1<d2<d3.

[0272] Embodiment 63 is an optical coupling element according to embodiment 61 or 62, wherein at least one of the first portion and the second portion of the landing area includes at least one scraped portion extending along the first direction.

[0273] Embodiment 64 is an optical coupling component, which includes an optical coupling element according to embodiment 63 and an optical waveguide received in and supported by the at least one groove, wherein the at least one scraped portion is formed when at least one of the first portion or the second portion of the landing area is scraped when the optical waveguide is received in and supported by the at least one groove.

[0274] Embodiment 65 is an optical coupling component according to embodiment 64, wherein for the at least one groove, the groove also includes a bottom surface and relative side walls extending upward from relative lateral sides of the bottom surface, and the at least one scraped portion includes a scraped portion of at least one side wall.

[0275] Embodiment 66 is an optical coupling component according to embodiment 64 or 65, wherein for the at least one groove, the groove also includes a bottom surface, and the at least one scraped portion includes a scraped portion of the bottom surface.

[0276] Embodiment 67 is an optical coupling component, which includes an optical coupling element according to any one of embodiments 55 to 63 and an optical waveguide received in and supported by the at least one groove, wherein a central ray propagating along the optical waveguide makes an angle of less than 1 degree, or less than 0.5 degrees, or less than 0.2 degrees with the bottom of the groove in at least a portion of the optical waveguide, and the at least a portion contacts the bottom surface of the groove in at least a portion of the supporting area adjacent to the first narrowing area.

[0277] Embodiment 68 is an optical coupling component, comprising an optical coupling element according to any one of embodiments 55 to 63 and an optical waveguide received in and supported by the at least one groove, wherein a central ray propagating along the optical waveguide makes an angle of less than 1 degree, or less than 0.5 degrees, or less than 0.2 degrees with the first direction in at least a portion of the optical waveguide disposed between the first narrowing region and the end face of the optical waveguide.

[0278] Embodiment 69 is an optical coupling component, which includes an optical coupling element according to any one of embodiments 55 to 63 and an optical waveguide received in a groove in at least one of the grooves and supported by the groove, the groove including a bottom surface extending between the front end and the rear end of the groove, and including a raised bottom surface portion that is raised upward relative to the unraised bottom surface portion, the unraised bottom surface portion of the bottom surface is arranged between the raised bottom surface portion of the bottom surface and the input side of the light redirecting member, the optical waveguide contacts the raised bottom surface portion above at least a continuous portion of the raised bottom surface, the continuous portion including an end of the raised bottom surface portion adjacent to the unraised bottom surface portion, wherein a central ray propagating along the optical waveguide makes an angle of less than 1 degree, or less than 0.5 degrees, or less than 0.2 degrees with the bottom of the groove in the continuous portion.

[0279] Embodiment 70 is an optical coupling component, comprising an optical coupling element according to any one of embodiments 55 to 63 and an optical waveguide received in and supported by the at least one groove, wherein a central ray leaving an end face of the optical waveguide makes an angle of less than 1 degree or less than 0.5 degree with the first direction.

[0280] Embodiment 71 is an optical coupling element according to any one of embodiments 55 to 63, wherein for the at least one groove, the groove includes a bottom surface, the bottom surface extends between the front end and the rear end of the groove and includes a raised bottom surface portion raised upward relative to the unraised bottom surface portion, and the unraised bottom surface portion of the bottom surface is arranged between the raised bottom surface portion of the bottom surface and the input side of the light redirecting member.

[0281] Embodiment 72 is a method for installing an optical fiber to an optical coupling element, the optical coupling element comprising a light redirecting member and a groove, the groove extending along a first direction from an entrance end of the groove to an opposite end of the groove near an input side of the light redirecting member, the groove having a width along a second direction orthogonal to the first direction and a depth along a third direction orthogonal to the first direction and the second direction, the groove comprising a bottom surface extending between the entrance end and the end of the groove and comprising a raised bottom surface portion raised upward relative to a landing portion, the landing portion of the bottom surface being disposed between the raised bottom surface portion of the bottom surface and the input side of the light redirecting member, the landing area of ​​the groove comprising the landing portion of the bottom surface and being disposed between the raised bottom surface portion of the groove and the end, the method comprising inserting the optical fiber into the groove so that a portion of the landing area of ​​the groove is scraped.

[0282] Embodiment 73 is a method according to embodiment 72, wherein inserting the optical fiber into the groove comprises:

[0283] inserting an end portion of the optical fiber into the groove so that the end portion comes into contact with the landing portion;

[0284] lowering the optical fiber into the groove until the optical fiber rests on the raised portion of the bottom surface; and

[0285] The optical fiber is moved along the first direction until the end of the optical fiber contacts the stop region.

[0286] Embodiment 74 is a method according to embodiment 73, wherein lowering the optical fiber into the groove forms a gap between the end of the optical fiber and the landing portion.

[0287] Embodiment 75 is a method according to embodiment 73 or 74, wherein inserting the end of the optical fiber into the groove includes positioning the optical fiber so that the axis of the optical fiber near the end of the optical fiber is at an oblique angle to the first direction.

[0288] Embodiment 76 is a method according to any one of embodiments 73 to 75, wherein at least one of the steps of inserting the end of the optical fiber or lowering the optical fiber includes scraping a portion of the landing portion of the bottom surface.

[0289] Embodiment 77 is a method according to any one of embodiments 73 to 76, wherein the step of moving the optical fiber includes scraping a portion of at least one of the opposing first and second side walls of the groove in the landing area.

[0290] Embodiment 78 is a method according to any one of embodiments 73 to 77, wherein the groove includes a first narrowing area, and the landing area is arranged between the first narrowing area and the end of the groove, and the minimum width of the groove in the first narrowing area is smaller than the width of the groove in an adjacent portion of the landing area.

[0291] Embodiment 79 is a method according to any one of embodiments 73 to 78, wherein the groove is the first groove among a plurality of substantially parallel grooves extending along the first direction and arranged along the second direction, and the optical coupling element includes the plurality of substantially parallel grooves.

[0292] Embodiment 80 is a method according to embodiment 79, wherein the optical fiber is a first optical fiber among a plurality of optical fibers, and the method includes mounting the plurality of optical fibers to the optical coupling element.

[0293] Embodiment 81 is a method according to embodiment 80, the method also comprising positioning the plurality of optical fibers in an alignment comb.

[0294] Embodiment 82 is a method according to embodiment 81, comprising:

[0295] inserting an end portion of each of the plurality of optical fibers into a corresponding groove of the plurality of grooves such that each end portion makes contact with a landing portion of the corresponding groove;

[0296] lowering each optical fiber into the corresponding groove by lowering the alignment comb until the optical fiber rests on a raised portion of a bottom surface of the corresponding groove; and

[0297] Each optical fiber is moved along the first direction until the end of the optical fiber contacts a stop region of the corresponding groove.

[0298] Embodiment 83 is a method according to embodiment 82, the method further comprising inspecting the plurality of optical fibers positioned in the plurality of grooves for the presence of interference fringes during at least one of the lowering step and the moving step.

[0299] Embodiment 84 is a method according to embodiment 83, which also includes adjusting the position of the alignment comb to reduce any observed interference fringes.

[0300] If it is not clear to one of ordinary skill in the art in the context of use and description in this specification that "about" applies to quantities expressing characteristic sizes, quantities, and physical properties, then "about" will be understood to mean within 10% of the specified amount, but also includes the exact specified amount. For example, if it is not clear to one of ordinary skill in the art in the context of use and description in this specification, then a quantity having a value of about 1 means that the quantity has a value between 0.9 and 1.1, and also includes a value of exactly 1.

[0301] All references, patents or patent applications cited above are hereby incorporated by reference in their entirety in a consistent manner. In the event of inconsistencies or conflicts between the incorporated references and this application, the information in the foregoing description shall prevail.

[0302] Unless otherwise indicated, the description of the elements in the drawings should be understood to apply equally to the corresponding elements in the other drawings. Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that the specific embodiments shown and described may be replaced with a variety of alternative and / or equivalent implementations without departing from the scope of the present disclosure. The present application is intended to cover any modification or variation of the specific embodiments discussed herein. Therefore, the present disclosure is intended to be limited only by the claims and their equivalents.

Claims

1. An optical coupling assembly, comprising: An optical coupling element, the optical coupling element comprising: a groove for receiving and aligning an optical waveguide and comprising an open front end, a rear end, and a bottom surface extending between the front end and the rear end of the groove; A light redirecting member, the light redirecting member comprising: an input side for receiving light from an optical waveguide received and supported in the groove; and a light redirecting side for changing the direction of light received from the input side; and an optical waveguide received in and supported by the groove, the optical waveguide having an end surface located at or near the input side of the light redirecting member, the optical waveguide comprising adjacent first and second segments, the second segment being disposed between the first segment and the input side of the light redirecting member and comprising the end surface of the optical waveguide, such that a bottom-most portion of the optical waveguide along the first segment of the optical waveguide rests on and is in physical contact with the bottom surface of the groove, and a bottom-most portion of the optical waveguide along the second segment of the optical waveguide is spaced apart from the bottom surface, thereby defining a gap between the bottom-most portion of the optical waveguide along the second segment and the bottom surface.

2. A method of installing an optical fiber to an optical coupling element, the optical coupling element comprising a light redirecting member and a groove, the groove extending along a first direction from an entrance end of the groove to an opposite end of the groove near an input side of the light redirecting member, the groove having a width along a second direction orthogonal to the first direction and a depth along a third direction orthogonal to the first direction and the second direction, the groove comprising a bottom surface extending between the entrance end and the end of the groove and comprising a raised bottom surface portion raised upwardly relative to a landing portion, the landing portion of the bottom surface being disposed between the raised bottom surface portion of the bottom surface and the input side of the light redirecting member, a landing area of ​​the groove comprising the landing portion of the bottom surface and disposed between the raised bottom surface portion of the groove and the end, the method comprising inserting the optical fiber into the groove such that a portion of the landing area of ​​the groove is shaved.

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