Optical fiber connector device and manufacturing method thereof

Abstract

The invention discloses a fiber optic connector device and a method of manufacturing the same, the fiber optic connector comprising a fiber optic positioning assembly and a frame having two walls for supporting the fiber optic positioning assembly such that it maintains a controlled vertical alignment with respect to the frame. The fiber positioning assembly includes an optical fiber array located on a top surface of a support block for positioning between the two walls, and a cap covering tops of the optical fibers protruding from the support block. The cap has a flat alignment surface on the cap that rests against the top of the optical fiber and extends laterally out of the support block such that when the support block is placed between the walls, a free portion of the alignment surface rests against the walls to control vertical alignment of the array. Horizontal alignment of the array can be controlled by a single guide rail fixed on a frame at the bottom of the frame and a rectangular groove with a corresponding size at the bottom of the supporting block.

Description

Technical Field

[0001] The present invention relates to optical communication systems and components thereof, and in particular to optical connectors. Background Art

[0002] Optical interconnects capable of high-density data communication are very useful in data communication and processing systems, such as large data centers and computer systems supporting artificial intelligence (AI) computing. In order to reduce power consumption and simplify the manufacture and installation of data service equipment, such interconnects are preferably passive, pluggable, and capable of interconnecting two high-density optical fiber arrays, or connecting a high-density optical fiber array to a silicon photonic chip. Summary of the invention

[0003] One aspect of the present disclosure provides an optical connector. The optical connector includes a frame and a positioning assembly. The frame includes a frame and two walls extending therefrom, the two walls being spaced apart to form a longitudinally extending groove. The positioning assembly is used to position an optical fiber array in the groove so as to optically couple with an optical device disposed in the groove. The positioning assembly includes an optical fiber support and a cap fixed thereon. The optical fiber support includes a planar top surface with a plurality of longitudinal grooves on the top surface, the optical fiber array being located in the groove, and the top of the optical fiber array being out of the top surface of the optical fiber support. The cap is fixed to the optical fiber support and has an alignment surface that rests on the top portion of the optical fiber array. The cap is wider than the optical fiber support, so that when the positioning assembly is placed in the groove in a working position, the free portion of the cap alignment surface rests on the wall to control the vertical alignment of the optical fiber support in the groove.

[0004] One aspect of the present disclosure provides a method for manufacturing an optical connector, the method comprising polishing an alignment surface of a cap and a top surface of a wall of a frame to sub-micron flatness, and fixing the cap to a fiber support, with the alignment surface resting on the top of a fiber array and with the alignment surface having free portions on both sides thereof laterally extending beyond the fiber support. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Example embodiments disclosed herein will be described in more detail with reference to the accompanying drawings, which are not drawn to scale and in which like elements are indicated by like reference numerals, and in which:

[0006] Figure 1 is a cross-sectional view of an optical connector in one embodiment, the optical connector including a fiber positioning assembly disposed in a frame;

[0007] Figure 2 is a cross-sectional view of an optical connector in one embodiment, the optical connector comprising a clamping shell;

[0008] Figure 3 yes Figure 1 or Figure 2A perspective view of an optical connector frame;

[0009] Figure 4 is a plan view of an optical connector assembly in one embodiment, the assembly including an optically coupled optical device located in the same housing. Figure 1 Fiber optic positioning components;

[0010] Figure 5 yes Figure 1 A flow chart of a method for manufacturing an optical connector;

[0011] Figure 6 yes Figure 1 A flow chart of a method for manufacturing a lateral alignment structure of an optical connector;

[0012] Figures 7A-7F yes Figure 1 Cross-sectional views of different components of the fiber optic positioning assembly at different stages of manufacture;

[0013] Fig. 8A is a cross-sectional view of an optical connector frame before longitudinally extending guide rails are mounted thereon to facilitate lateral alignment;

[0014] Figure 8B is a cross-sectional view of an optical connector frame sized to receive the optical connector in both vertical and lateral control positions. Figure 7F Fiber optic positioning components;

[0015] Fig. 9 is a perspective view of an optical connector device in one embodiment. DETAILED DESCRIPTION

[0016] In the following description, specific details, such as specific circuits, circuit elements, technologies, etc., are listed for the purpose of explanation rather than limitation, so as to provide a thorough understanding of the present disclosure. However, it is obvious to those skilled in the art that the present disclosure may be implemented in other embodiments that deviate from these specific details. In other cases, detailed descriptions of well-known methods, devices, and circuits may be omitted to avoid blurring the description of the present disclosure. All statements of the principles, aspects, and embodiments disclosed herein and specific examples thereof are intended to include their structural and functional equivalents. In addition, these equivalents include both currently known equivalents and equivalents developed in the future.

[0017] It should be noted that the terms "first", "second", etc. used herein do not imply sequential ordering, but are used to distinguish one element from another, unless explicitly stated. Similarly, unless explicitly stated, the order of method steps does not imply a requirement for sequential execution. Unless explicitly stated otherwise, the term "connected" may include direct connection or indirect connection through intermediate elements.

[0018] Figure 1 1 is a cross-sectional view of an optical connector device 100 ("optical connector 100") according to an exemplary embodiment. The optical connector 100 and its elements or embodiments hereinafter may be described with reference to a rectangular coordinate system (x, y, z) 11, wherein the z-axis of the rectangular coordinate system (x, y, z) 11 is along the light propagation direction in the optical connector, also referred to herein as the longitudinal direction. Figure 1 The optical connector 100 is shown in cross-section on the coordinate system 11 (x, y) plane. The optical connector 100 includes a positioning assembly 140 ("assembly 140") and a frame 110. The frame 100 includes a shelf 114 and two walls 112 extending from the shelf to form a groove 115. The assembly 140 is disposed between the two walls 112 of the groove 115. The two walls 112 are used to support the positioning assembly 140 in a precisely controlled vertical position within the frame, and therefore may also be referred to as support walls. The two sides of the groove 115 are defined by the support walls 112 and are perpendicular to the groove 115. Figure 1 The plane extends in the longitudinal direction of the frame 110. Portions of the assembly 140 are arranged to abut against the wall 112. The height of the wall 112 controls the vertical positioning of the assembly 140 relative to the frame 110, as will be further described below.

[0019] The positioning assembly 140 may include a fiber support 130 and a cap 120 connected thereto. The fiber support 130 may be, for example, a glass block or the like. Other materials suitable for the fiber support 130 include, but are not limited to, polycarbonate, silicon, or silicon dioxide. The fiber support 130 may also be referred to as a fiber support block 130, and one or more grooves 135 are formed on its upper surface 133. The grooves 135 may be, for example, V-shaped grooves, and one or more optical fibers 152 are located in each groove 135. The height of the fiber support 130 may be slightly less than the height of the wall 112, that is, it may be less than the depth of the groove 115. The top surface 133 of the fiber support 130 between and around the grooves 135 may be a plane, so that the plurality of grooves 135 are approximately located in the same plane. In the example, the fiber support 130 includes a plurality of V-shaped grooves 135 extending longitudinally to each other, for supporting an array 150 of optical fibers 152. The top of the optical fiber 152 protrudes from the top surface 133 of the support 130.

[0020] The cap 120 is fixedly connected to the support 130 for covering the optical fiber 152. For example, the cap 120 can be fixedly connected to the top surface 133 of the support 130. A surface 123 of the cap 120 is located on the top of the optical fiber 152, preferably in direct contact with the optical fiber 152. The surface 123 of the cap 120 has a high degree of flatness, so the top of the optical fiber 152 is consistent with the surface 123 of the cap, and is also horizontally aligned. The surface 123 of the cap 120 can be referred to as the alignment surface 123 herein. The cap 120 is wider than the optical fiber support 130, so the cap 120 and the alignment surface 123 have free parts on both sides that extend horizontally and exceed the support 130, so that when the optical fiber support 130 is in the working position in the frame 110, it can be abutted against the wall 112 of the frame 110. Here and in the following embodiments, the horizontal direction or lateral direction is the direction perpendicular to the V-groove 135 along the alignment surface 123 (the x-axis of the coordinate system 11), and the direction perpendicular to the alignment surface 123 (the y-axis) is called the vertical direction or transverse direction. For example, the cap 120 can be a plate made of a suitable material. Suitable materials can be, for example, glass or other suitable materials, including but not limited to polycarbonate, silicon or silicon dioxide, and are thick enough to prevent or at least reduce deformation due to handling or environmental effects. For example, the cap 120 can be a glass plate with a thickness of 0.2 mm to 2 mm.

[0021] Walls 112 may have planar top surfaces 113, and the top surfaces may be arranged to lie in the same horizontal plane, i.e., the (x, z) plane of coordinate system 11. Thus, when assembly 140 is in the operating position, top surface 113 of wall ("support surface 113") is in direct face-to-face contact with the free portion of alignment surface 123, and fiber support 130 is located in groove 115 between walls 112. Surfaces 113 and 123 may be polished to a high degree of flatness to precisely control the vertical positioning of assembly 140 when optical fiber 152 is in groove 115. In one embodiment, surfaces 123, 133, or at least portions thereof in direct contact, may each be polished to a sub-micron flatness tolerance when assembly 140 is supported by frame 110 in the operating position. For example, surfaces 123, 133 may each be flattened to a flatness tolerance of 0.5 μm, or preferably 0.2 μm. Here, the "flatness" and "flatness tolerance" of a surface are used interchangeably to refer to the minimum distance between two parallel planes with which the surface must mate. In certain embodiments that specify a target operating wavelength λ of the optical connector 100, the flatness specification of the surfaces 113, 123 along the area of ​​their interface 123 / 113 can be λ / 2, or λ / 3, or preferably λ / 4. For example, λ=0.6μm, the surfaces 123, 133 can be polished to a flatness of 0.3μm, 0.2μm, or 0.15μm, respectively.

[0022] In some embodiments, the fiber support 130 may have a lateral alignment feature 138 that may mate with a corresponding lateral alignment feature 160 of the frame 110. The lateral alignment feature 138 may be located at a predetermined lateral position relative to the V-groove 135, such as laterally centered, with a positioning accuracy tolerance of sub-micron level. The lateral alignment features 138, 160 are used to control the lateral positioning of the fiber support block 130 between the walls 112. In the illustrated example, the lateral alignment feature 138 is a groove extending longitudinally at the bottom of the fiber support block 130. The lateral alignment feature 160 of the frame 110 is a longitudinally arranged rail connected to the surface 118 of the shelf 114 between the walls 112, and its size matches the groove 138. In one embodiment, the groove 138 has a rectangular cross-section, and the rail 160 is a cylindrical rod, whose size matches the groove 138, and leaves a small margin to allow movement along it. For example, the groove 138 can be 0.5 μm to 5 μm wider than the rail 160. Here, the terms "width", "wider", etc. refer to the lateral dimension of the corresponding element, i.e., the width along the horizontal direction. Figure 1 The term "height" refers to the vertical dimension of the corresponding element, i.e., the dimension along the x-axis. Figure 1 The inner sidewalls of the groove 138 may be flat, with a sub-micron flatness, such as a flatness of 0.5 μm or more, and along the areas where they may contact each other. The outer surface of the guide rail 160 may also be flat along the length direction in contact with the walls of the groove 138, such as to achieve the same flatness tolerance, as described below.

[0023] In some embodiments, the positioning assembly 140 can be inserted into the frame 110. For example, the positioning assembly 140 is removably inserted into the groove 115 between the walls 112. In some embodiments, the positioning assembly 140 can slide along the groove 115 to a target position in the groove 115. In some embodiments, the positioning assembly 140 can be fixedly disposed in the groove 115, for example, glued in the groove 115.

[0024] Figure 2 A fiber optic connector 200 is shown, which may be one embodiment of the optical connector 100 . Figure 1 and Figure 2The same elements in the embodiment are indicated by the same reference numerals and will not be described again. The optical fiber connector 200 has an additional clamping shell 170 for vertically fastening the cap 120 to the wall 112 of the frame 110. In this example, the additional clamping shell 170 is configured to fix the assembly 140 in the groove 115 of the frame 110. In some embodiments, the clamping shell 170 is removable. An elastic load 166 such as a spring can be set in the housing 170 to push the cap 120 to fix the assembly 140 in the groove 115, ensuring that the free part of the alignment surface 123 of the cap 120 is in direct contact with the support surface 113 at the top of the support wall 112. In some embodiments, other elastic loads can also be used to achieve this purpose, such as a piece of elastic material, such as rubber or rubber-like material. These materials can be attached to the inside of the clamping shell 170, for example, glued to its top inner surface.

[0025] refer to Figure 3 and Figure 4 , the length 311 that the frame 110 extends in the longitudinal direction (z-axis) is sufficient to accommodate the two positioning assemblies 140. The two positioning assemblies 140 are arranged one behind the other over this length, and their respective caps 120 are placed on the wall 112 at corresponding positions along the grooves 115. Advantageously, aligning the fiber arrays of the two assemblies with the top surface 113 of the same support wall 112 can ensure that the fiber arrays are well vertically aligned with each other to achieve the flatness specifications of their respective contact surfaces. Aligning the optical fibers of the two fiber positioning assemblies laterally with the same guide rail 160 can promote good lateral alignment of the corresponding optical fibers of the two arrays with each other, which is determined in part by the lateral positioning accuracy of the alignment grooves at the bottom of each fiber positioning assembly relative to the corresponding optical fiber array.

[0026] Figure 4 A top view of an optical connector assembly 400 is shown. The optical connector assembly 400 optically couples the optical fiber array 150 to an optical device 410 that supports an optical waveguide array 450. The optical connector assembly 400 includes a frame, such as the frame 110 described above, having support walls 112 and guide rails 160 extending along the same. As described above, the fiber positioning assembly 140 supports the ends of the optical fiber array 150 in corresponding V-shaped grooves. The fiber positioning assembly 140 and the optical device 410 are aligned on the guide rails 160 between the walls 112, and both are abutted against the guide rails 160 as described above with reference to FIG. Figure 1-3 The wall 112. The lateral alignment of the fiber positioning assembly 140 and the optical device 410, i.e., their relative positioning along the x-axis, is controlled by the guide rail 160. The fiber positioning assembly 140 is configured to be insertable into the frame of the optical connector 400. In some embodiments, an optical lens element 430, such as a microlens array, is used to facilitate optical coupling of the fiber array 150 with the optical fiber or optical waveguide array of the optical device 410.

[0027] For example, the optical device 410 may include another fiber positioning assembly 440, similar to the fiber positioning assembly 140, for supporting the fiber array 450 aligned with the cap 420 against the wall 112. The fiber positioning assembly 440 may be pluggable or fixed to a frame of the optical connector 400, such as the frame 110 described above. The vertical alignment of the proximal optical fibers of the fiber arrays 150, 450, i.e., their alignment along the wall 112, may be performed by the optical device 410. Figure 4 The alignment of the plane normal y-axis is controlled by aligning each of the optical fiber arrays 150, 450 with the top surface of the same wall 112. Alternatively, the optical device 410 may include an optoelectronic chip, the top surface of which includes a planar optical waveguide array, a cap or carrier 420 attached to the surface of the chip where the optical waveguide array is located, and a free portion of the carrier resting against the wall 112. In some embodiments, the optoelectronic chip may be attached to the frame 110.

[0028] The following will refer to Figure 5-8B Methods of making an optical connector (eg, connector 100, 200, or 400) having features of the present disclosure are described.

[0029] Figure 5 1 is a flow chart for illustrating some steps of a method 500 for manufacturing an optical connector, such as the optical connectors 100, 200, or 400 described above. In different embodiments, some of these steps may be omitted, and / or other steps may be added. In the illustrated example, the method 500 may begin with step 510, wherein a fiber support, such as the fiber support 130; and a cap, such as the cap 120, are provided. The fiber support has an optical fiber array, such as the optical fiber array 150, which is arranged in an array of grooves formed on the top surface of the fiber support, such as the V-groove 135. The optical fibers in the V-groove are arranged along the longitudinal direction ( Figure 3 , Figure 4 The size of the groove is designed so that when the optical fiber array is placed in the groove, the top of the optical fiber protrudes from the top surface of the optical fiber support, as described above. Figure 1 and below Figure 7B In the transverse direction of the V-shaped groove, the cap is wider than the optical fiber support, usually 0.5 to 2 mm or more.

[0030] In various embodiments, step 510 may include one or more sub-steps. For example, a V-groove is made on the flat top surface of the fiber support or the support substrate described below, the end of the fiber array is placed in the V-groove, and one side of the cap is polished to sub-micron flatness to provide an alignment surface, such as surface 123. For example, the flatness tolerance of the alignment surface, such as surface 123, is typically about or better than 0.5 μm, or preferably about 0.2 μm or less. In certain embodiments of manufacturing an optical connector for a target operating wavelength λ, the alignment surface of the cap can be prepared, such as polished, to achieve a flatness specification of a specific wavelength fraction, such as a flatness of λ / 2 or better, or preferably λ / 4.

[0031] In step 520, a fiber positioning assembly, such as the fiber positioning assembly 140 described above, is manufactured. This step includes attaching a cap (e.g., 120) to an upper surface (e.g., 133) of a fiber support (e.g., 130). The cap is placed on the fiber array (e.g., 150) so that the flat alignment surface (e.g., 123) of the cap is against the top of the fiber array and the free portion of the cap extends laterally beyond the fiber support, as described above. Figure 1 and below Figure 7C The resulting subassembly can be coated with a layer of glue (such as 120) in the gap between the cap (such as 120) and the top surface of the fiber support (such as 133). Figure 7C 712 in). Before the glue solidifies, the cap can be forced toward the optical fiber to ensure that the alignment surface of the cap is in direct contact with each optical fiber along the groove, so that the optical fiber reaches the flatness specification of the alignment surface at the top. This operation can make the optical cores of the optical fibers roughly aligned with each other. The mutual alignment of the cores of the optical fiber array may be mainly or at least partially limited by the variation of the core-cladding concentricity of the optical fiber. For example, the concentricity tolerance of the optical fiber is typically less than 0.5μm, so that the optical fiber cores can be aligned along the same plane with sub-micron accuracy.

[0032] Step 530 includes providing (e.g., manufacturing) a frame in which the fiber positioning assembly can be precisely (e.g., sub-micron) aligned with another optical device similarly positioned within the frame. The frame, such as frame 110 described above, has two walls, such as wall 112, spaced apart to accommodate a fiber support with a cap attached, such that a free portion of an alignment surface of the cap abuts against the wall to control the vertical alignment of the fiber support within the groove, such as frame 110 described above. Figure 1-4 This step may include preparing the top surface of the wall by polishing or the like so that it is flat along the length direction, such as Figure 3 311 in, reaching the submicron level. For example, the top surface of the wall can be prepared to have a submicron level flatness that is approximately the same as the alignment surface of the cap, for example, the flatness specification is usually 0.5 μm or higher, or the flatness is 0.2 μm or higher. The length of the groove, for example Figure 3The length 311 in the groove may be sufficient to accommodate, for example, two optical fiber positioning components arranged longitudinally in sequence in the groove, or an optical fiber positioning component and an optical chip attached to the carrier cap, such as the above Figure 4 The flat top surface of the frame wall provides a common vertical alignment reference for two optical devices placed in the groove and supported by the common wall.

[0033] Optional step 540 includes placing the optical positioning assembly made in step 530 into the groove of the frame so that the free portion of the cap rests on the flat top surface of the frame wall and preferably directly contacts it.

[0034] Steering Figure 6 In some embodiments, a method for manufacturing an optical connector, such as method 500, may include a method 600 for manufacturing a lateral alignment structure for controlling the lateral positioning of a fiber optic positioning assembly between frame walls, such as structures 138 and 160 described above for frame 110 and positioning assembly 140. Figure 7C-8B An example implementation of method 600 is shown. Method 600 may include (610) installing a longitudinal rail (such as rail 160) between walls (such as 112) of a chassis of a frame (such as 110). In some embodiments, rail 160 may be a right circular cylinder with a polished surface, for example, with a flatness in the length direction of about 0.5 μm or more, or preferably about 0.2 μm or more. Here, "flatness in the length direction" refers to the range of variation along the rail of the minimum distance from the rail to a plane parallel to the rail.

[0035] The method 600 may further include (620) connecting a pair of plates (eg, as described below) side by side at the bottom of the fiber support or substrate. Fig.7D and 7E 720A and 720B described). When connecting the two plates, the flat sides of the plates can be facing each other and spaced apart at the bottom of the assembly to form a longitudinally extending rectangular groove so that the fiber positioning assembly can cooperate with the guide rail when placed between the frame walls. The method may include preparing the sides of the plates facing each other in the assembly so that they have sub-micron flatness along the length of the fiber positioning assembly, for example, polishing the sides of the plates before securing the plates to the substrate. For example, the sides of the plates can be polished to a flatness of about 0.5 μm or more, or preferably a flatness of about 0.2 μm or more. In one embodiment, the preparation of the guide rail and the plate can achieve a surface-to-surface flatness of 0.5 μm or more, or preferably about 0.2 μm or more at the interface between the guide rail and any side of the plate forming the groove.

[0036] First reference Fig. 7A and 7BIn one embodiment, the process of method 500 may begin by manufacturing or otherwise obtaining a fiber support substrate 710 having a plurality of V-grooves 735 formed in a top surface 733 thereof. The V-grooves 735 and the top surface 733 are respectively Figure 1 and Figure 2 The top surface 133 and the V-groove 135 of the optical fiber support member 130 are shown in FIG. The substrate 710 may be a glass substrate or the like, or may be a substrate of other suitable materials, including but not limited to polycarbonate, silicon or silicon dioxide. The V-groove 735 may be formed by any suitable process known in the art, such as by precision cutting or etching. Figure 7B As shown, the optical fiber 152 array can be placed in a V-groove 735. The size of the V-groove 735 allows the top of the optical fiber 152 to protrude above the top surface 733 of the substrate 710. For example, the height of the portion of the optical fiber 152 above the top surface 733 can be 10% to 30% of the diameter of the optical fiber, such as about 10 to 40 μm.

[0037] refer to Figure 7C , the process may further include placing the cap 120 on top of the optical fiber 152 on the substrate 710 so that the alignment surface 123 of the cap 120 is in direct contact with the top of the optical fiber 152 extending from the top surface 733. This step may include allowing some of the optical fibers 152 to penetrate into the corresponding V-grooves 735 so that the tops of all the optical fibers 152 are aligned along the alignment surface 123 of the cap 120. This also aligns the optical cores of the optical fibers 152 to achieve fiber diameter and concentricity variation tolerances. The cap 120 can then be attached to the substrate 710. For example, the gap 712 between the cap 120 and the top surface 733 of the substrate 710 can be filled with a suitable glue and then cured as needed.

[0038] refer to Figure 7D-7F , the groove at the bottom of the fiber positioning assembly (e.g., 740) can be formed by connecting two plates 720A and 720B to the bottom surface of the substrate 710, the two plates being side by side but at a certain distance 746 from each other to form a fiber support 730. Connecting the two plates 720A and 720B to the bottom surface of the substrate 710 may include bonding the plates 720A, 720B to the bottom surface of the substrate 710. Prior to connection, the sides 721 of the plates 720A, 720B facing each other in the assembly 740 can be polished to a desired flatness. For example, as described above, polished to λ / 2, λ / 3, or λ / 4 flatness, or, for example, polished to a flatness specification of 0.5μm or higher or 0.2μm or higher. The fiber support 730 is an example of the fiber support 130. In the finished assembly, the thickness of the glue layer 712 between the bottom surface of the substrate 710 and the plates 720A, 720B can be controlled, for example, with an accuracy of +\-2 μm.

[0039] In one embodiment, an oversized rail member 744 may be used during the assembly phase to precisely position the plates 720A, 720B to a target 717 on the bottom of the substrate 710. The width of the oversized rail member 744 may be equal to the target spacing 746 between 720A, 720B. The process may include providing a target 717 on the bottom of the substrate 710 that is disposed relative to a predetermined position of the V-grooves 733, such as laterally aligned with the central axis of the V-groove array. The target 717 indicates the groove 725 ( Figure 7F ) position. The process may include temporarily placing the oversized rail member 744 longitudinally next to the bottom surface of the substrate 710, precisely aligned with the target 717, and placing the plates 720A and 720B against the oversized rail member 744 on their opposite sides so that the polished sides 721 of the plates 720A and 720B are arranged opposite each other and form the inner side walls of the groove 725 ( Figure 7F ). Groove 725 is an example of groove 138. The width of oversized rail feature 744, and the spacing 746 between plates 720A and 720B in assembly 740, exceeds the width of the alignment rail (e.g., 160) connected to the connector frame chassis to some extent, such as by 0.5 μm to 5 μm.

[0040] Reference Fig. 8A and 8B , the connector manufacturing process may further include manufacturing the frame 110, the support wall 112 extending from the shelf 114, and gluing or welding the alignment guide 160 to the target position of the bottom surface 118 of the shelf 114. In one embodiment, the alignment guide 160 may be positioned in the middle of the width of the groove 115, at least one quarter or one third of the groove width away from the nearest wall 112, for example, approximately equal distance from both walls 112. The process may include polishing the top surface 113 of the wall 112 to a desired flatness, for example, if the operating wavelength λ is specified, polishing to λ / 2, λ / 3, or λ / 4, or as described above, polishing to a flatness of 0.5μm or 0.2μm in certain example embodiments. Figure 3 1 is a perspective view of the frame 110 with the rails 160 attached. The assembly 740 can then be placed in the groove 115 between the walls 112 so that the free portions 123A, 123B of the alignment surface 123 of the cap 120 are seated against the top surface 113 of the support wall 112, preferably in direct contact with the cap 120 and / or the assembly 740 along the entire length thereof. The length 311 ( Figure 3 ) That is, the length of the groove 115 therebetween can exceed the length of the fiber positioning assembly 140 or 740, for example, more than 2 times or more in some typical examples. The length 311 of the groove can accommodate the fiber positioning assembly 740 and another optical device, such as 410 ( Figure 4), due to the shared alignment structures 113 and 160, the two can be precisely optically aligned with each other.

[0041] Fig. 9 A perspective three-dimensional view of an embodiment 900 of an optical connector assembly according to the present disclosure is shown. In this example, the optical connector assembly 900 connects two optical fiber arrays, an optical fiber array 961 and an optical fiber array 962. The two optical fiber arrays are carried by respective fiber positioning assemblies, which are in turn located between support walls 912 of the connector frame and have caps 920, which are located on the support walls 912. A chuck 970 is shown in the figure for fixing one of the fiber positioning assemblies between the support walls 912. The support walls 912, the caps 920 and the chuck 970 are examples of the support walls 112, the caps 120 and the chuck 170 described above.

[0042] The optical connectors described above have significant advantages in terms of alignment accuracy and / or ease of manufacturing compared to the fiber optic connectors commonly used in the art. One of the advantages is that the optical fibers or planar optical waveguides carried by the two positioning assemblies are inherently aligned with the common support surface of the frame in some embodiments, thereby inherently promoting their mutual alignment in the vertical direction, that is, the normal direction of the fiber or waveguide array plane. This arrangement is more advantageous than more traditional connector designs, in which the two fiber positioning blocks are aligned at their top or bottom surfaces, and the top or bottom surface is away from the fiber support surface, which requires that the fiber positioning blocks must be completely aligned with each other. In addition, some connectors used in the art include two or more pins and two or more V-grooves of corresponding sizes for lateral alignment of the two fiber positioning blocks within the frame. However, this imposes unnecessary restrictions on the spacing accuracy between grooves and between pins, which may be detrimental to the yield of working connector assemblies. As described above, the use of a single alignment guide for lateral alignment, rather than two or more pins, eliminates this over-restriction problem because it eliminates the requirement for pin spacing accuracy, thereby simplifying the manufacturing process and potentially increasing yield. In addition, it is generally easier to polish the sides of the two glass plates to a desired flatness than to polish the inner walls of the V-groove. Thus, the above-described embodiments provide a passive optical connector that has a smaller footprint, may be easier to manufacture, and / or has a higher optical alignment accuracy, thereby having a lower optical insertion loss, compared to some typical optical connectors used in the art.

[0043] The above examples of optical connectors are not limiting, and many variations will be apparent to readers familiar with the present disclosure. For example, a fiber support such as 130 may be configured to support more than one optical fiber array, such as arranged side by side and / or one covering another.

[0044] One or more of the examples described above, such as in the Summary section and with reference to Figure 1-9 Any one or more of, providing an optical connector, comprising: a frame (e.g., 110, Figure 1-3 , 8A-9) and a positioning assembly (e.g., 140, 740). The frame includes a rack (e.g., 114, Figure 1 , 3 , 8A-9) and two walls extending from the shelf (such as 112, Figure 1-4 , 8A-9), with a gap between the two walls to form a longitudinally extending groove (such as 115). The positioning assembly is used to position an array (such as 150, 961, 962) of optical fibers (such as 152) in the groove to match the optical device (such as 410, Figure 4 ;920, Fig. 9 ) optical coupling; the optical fiber support (such as 130, 730) includes a flat top surface (such as 133, 733) having a plurality of longitudinal grooves (such as 135, 735); the optical fiber array is arranged in the grooves (such as 135, 735). The top of the optical fiber array protrudes from the top surface (such as 133, 733) of the optical fiber support; and a cap (such as 120) fixedly disposed on the optical fiber support, the cap has an alignment surface (such as 123) resting against the top of the optical fiber array. The cap is wider than the optical fiber support, so that when the positioning assembly is placed in the groove in the working position, the free portion of the alignment surface of the cap (such as 123A, 123B, Figure 8B ) against the wall to control the vertical alignment of the fiber support in the groove. During operation, the positioning assembly can be placed in the groove with the alignment surface of the cap against the wall.

[0045] In some embodiments, the wall of the frame can have a flat top surface, wherein the free portion of the alignment surface of the cap is in direct contact with the top surface of the wall when the fiber support is in the operative position in the groove. In certain embodiments, the top surface of the wall and the alignment surface of the cap can be planes each having sub-micron flatness.

[0046] In any of the above embodiments, the optical connector may further include a housing (e.g. Figure 2 170 of them Fig. 9 970) is used to fix the positioning assembly in the groove.

[0047] In any of the above embodiments, the optical connector can have a gap between the alignment surface of the cap and the top surface of the fiber support.

[0048] In any of the above embodiments, the flatness of the top surface of the wall and the alignment surface of the cap can reach 0.5 μm or higher.

[0049] In any of the above embodiments, the cap may be adhered to the top surface of the fiber support.

[0050] In any of the above embodiments, the positioning assembly may include a lateral alignment structure for controlling the lateral positioning of the fiber support between the walls. In some of these embodiments, the lateral alignment structure may include a longitudinally extending groove (e.g., 138, Figure 1 ;725, Figure 7F ), further comprising a guide rail (e.g., 160, longitudinally fixed to the shelf surface between the walls Figure 1-4 , 8B, 9), the size of the guide rail matches the groove to control the lateral positioning of the optical fiber support. In some embodiments, the guide rail may have a cross-section that is approximately circular. For example, the groove may be about 0.5 μm to 5 μm wider than the guide rail.

[0051] In any of the above embodiments, the groove may have two oppositely disposed flat inner surfaces with submicron flatness. In some of these embodiments, the two opposite inner surfaces of the groove may be the flat sides (such as 721) of a pair of plates (such as 720A, 720B).

[0052] In any of the above embodiments, the optical fiber support may include: an optical fiber support substrate (eg, 730, Figures 7A-8B ), the base plate includes a planar top surface with a V-shaped groove, and a pair of plates (e.g., 720A, 720B). The pair of plates are pasted side by side on the bottom surface of the supporting base plate to form a groove (e.g., 138, 725) therein for accommodating a guide rail (e.g., 160) connected to a shelf between the walls.

[0053] In any of the above embodiments, the optical connector may further include an optical device disposed between the walls, the optical device including one of the following: another optical fiber positioning assembly consisting of another optical fiber array and an optoelectronic chip.

[0054] One or more of the examples described above, such as in the Abstract section and referenced Figure 1-9 Any one or more of, a method for manufacturing an optical connector according to any of the above embodiments is provided. The method may include: polishing the alignment surface of the cap and the top surface of the wall of the frame to sub-micron flatness; and fixing the cap to the optical fiber support so that the alignment surface rests on the top surface of the optical fiber array and the alignment surface has free portions on both sides of the alignment surface that laterally extend beyond the optical fiber support. Certain embodiments of the method may include polishing to achieve a flatness of 0.5 μm or higher.

[0055] Any of the above embodiments may include mounting a longitudinally aligned guide rail to the surface of the shelf between the walls and forming a longitudinally extending groove on the bottom surface of the fiber support. The groove is located at a predetermined position relative to the fiber array. When the fiber support is placed in the groove between the walls, the groove is sized to accommodate the guide rail. Some of the embodiments may include a pair of alignment plates fixed side by side on the bottom surface of the fiber support substrate to form the fiber support, and the space between the proximal sides of the alignment plates defines the groove. Some of the embodiments may further include polishing the proximal surfaces of the pair of alignment plates to sub-micron flatness before installation.

[0056] Unless expressly stated otherwise, each numerical value and range should be interpreted as approximate as if the word "about" or "approximately" were preceded by the value or range.

[0057] It should be further understood that those skilled in the art may make various changes in the details, materials and arrangements of the parts described and illustrated for the purpose of explaining the content of the present invention without departing from the scope of the present disclosure, such as expressed in the claims.

[0058] The purpose of using figure numbers and / or figure labels in the claims is to identify one or more possible embodiments of the claimed subject matter to facilitate the interpretation of the claims. Such use should not be interpreted as necessarily limiting the scope of these claims to the embodiments shown in the corresponding figures.

[0059] References to "one embodiment" or "embodiment" herein mean that a particular feature, structure, or characteristic associated with the embodiment may be included in at least one embodiment of the present disclosure. The phrase "in one embodiment" appearing in different places in the specification does not necessarily refer to the same embodiment, and separate or alternative embodiments are not necessarily mutually exclusive with other embodiments. The same applies to the term "implementation".

[0060] In addition, in the above description, specific details, such as specific architectures, interfaces, technologies, etc., are set forth for the purpose of explanation rather than limitation, so as to provide a thorough understanding of the present disclosure. In some cases, detailed descriptions of well-known devices, circuits, and methods are omitted to avoid unnecessary details that obscure the description of the contents of the present disclosure. Therefore, for example, it will be understood by those skilled in the art that the block diagrams herein may represent conceptual views of illustrative circuits that embody the principles of the present technology. All statements describing the principles, aspects, and embodiments of the present disclosure herein and their specific examples are intended to cover their structural and functional equivalents.

[0061] Thus, while the present disclosure has been particularly shown and described with reference to the example embodiments shown in the drawings, it will be understood by those skilled in the art that various changes in details may be affected therein without departing from the spirit and scope of the disclosure as defined by the claims.

Claims

1. An optical connector, characterized in that: include: a frame including a frame and two walls extending from the frame, the two walls being spaced apart to form a longitudinally extending groove therebetween; A positioning assembly, used for positioning the optical fiber array in the groove to optically couple with an optical device disposed in the groove, the positioning assembly comprising: An optical fiber support member includes a flat top surface having a plurality of longitudinal grooves thereon; an optical fiber array disposed in the groove, the top of the optical fiber array protruding from the top surface of the optical fiber support; and A cap fixedly disposed on the optical fiber support, the cap having an alignment surface, the alignment surface resting on the top of the optical fiber array; The width of the cap is greater than the width of the optical fiber support, so that in the working position, when the positioning assembly is placed in the groove, multiple free parts of the alignment surface of the cap lean against the wall to control the vertical alignment of the optical fiber support in the groove.

2. The optical connector according to claim 1, wherein: The positioning assembly is located in the groove, and the alignment surface of the cap rests on the wall.

3. The optical connector according to claim 1, wherein: The two walls of the frame have flat top surfaces, and the free portions of the alignment surface of the cap are in direct contact with the top surfaces of the two walls when the optical fiber support is in the working position in the groove.

4. The optical connector according to claim 3, characterized in that The top surfaces of the two walls and the alignment surface of the cap are both planes, each having a sub-micron level of flatness.

5. The optical connector according to claim 3, wherein: Also included is a clamping shell for fixing the positioning assembly in the groove.

6. The optical connector according to claim 4, characterized in that The top surface of the wall and the alignment surface of the cap are both flat at 0.5 microns or higher.

7. The optical connector according to claim 3, characterized in that: The cap is glued to the top surface of the optical fiber support.

8. The optical connector according to claim 1, wherein: The positioning assembly includes lateral alignment structure for controlling lateral positioning of the fiber support between the walls.

9. The optical connector according to claim 8, characterized in that The lateral alignment structure includes a longitudinally extending groove on the bottom surface of the fiber support member, and also includes a guide rail longitudinally fixed on the surface of the shelf between the two walls, and the size of the guide rail matches the groove to control the lateral positioning of the fiber support member.

10. The optical connector according to claim 9, characterized in that The guide rail has an approximately circular cross section.

11. The optical connector according to claim 10, wherein: The groove is about 0.5 microns to 5 microns wider than the guide rail.

12. The optical connector according to claim 10, wherein: The groove has two opposing flat inner surfaces with sub-micron flatness.

13. The optical connector according to claim 12, wherein: The two opposing inner surfaces of the groove are flat side surfaces of a pair of plates.

14. The optical connector according to claim 13, wherein: The optical fiber support comprises: an optical fiber support substrate including a flat top surface with a V-shaped groove, and The pair of plates are fixed side by side on the bottom surface of the supporting substrate to form a groove therebetween.

15. The optical connector according to claim 1, wherein: The optical connector further includes an optical device disposed between the two walls, the optical device including one of the following devices: another optical fiber positioning assembly consisting of another optical fiber array and an optoelectronic chip.

16. A method for manufacturing the optical connector according to claim 1, characterized in that: include: polishing the alignment surface of the cap and the top surfaces of the two walls of the frame to sub-micron flatness; as well as The cap is mounted on the fiber support with the alignment surface resting on the top of the fiber array and with the alignment surface having free portions on both sides thereof extending laterally beyond the fiber support.

17. The method for manufacturing an optical connector according to claim 16, wherein: include: Polishing is performed to achieve a flatness of 0.5 μm or higher.

18. The method for manufacturing an optical connector according to claim 16, wherein: Also includes: Install the longitudinally aligned rails onto the shelf surface between the walls; as well as A longitudinally extending groove is formed in the bottom surface of the fiber support, the groove being located at a predetermined position relative to the fiber array and having a size to receive the guide rail when the fiber support is placed into the groove between the walls.

19. The method for manufacturing an optical connector according to claim 18, wherein: include: A pair of alignment plates are fixed side by side on the bottom surface of the fiber support substrate to form a fiber support member, and the space between the proximal surfaces of the alignment plates defines a groove.

20. The method for manufacturing an optical connector according to claim 19, wherein: The method includes polishing the proximal surfaces of the pair of alignment plates to a sub-micron level of flatness before fixing the alignment plates.

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