Two-dimensional optical fiber array with high return loss and manufacturing method

Abstract

The invention relates to the field of optical device manufacturing, and provides a high-return-loss two-dimensional optical fiber array and a manufacturing method. The invention provides a two-dimensional optical fiber array with high return loss, which comprises a substrate and a plurality of optical fibers, and is characterized in that the plurality of optical fibers are arranged on the substrate and are arranged on the substrate in a two-dimensional array form; a plurality of inclined planes are ground on the surface of the substrate, and each inclined plane inclines by a preset angle relative to the reference plane, so that the end face of each optical fiber is ground to a preset angle. The invention further provides a manufacturing method of the high-return-loss two-dimensional optical fiber array, the substrate of the two-dimensional optical fiber array makes contact with the first grinding face of the annular grinding disc according to the preset angle, the annular grinding disc is controlled to rotate around the circle center, the two-dimensional optical fiber array is controlled to do reciprocating swing motion along the straight line where the optical fiber in the current row is located, and the optical fiber in the current row is obtained. The end face of each optical fiber is ground into a preset angle; the problem that return loss is low due to the fact that return light energy enters a light path of the optical fiber is solved.

Description

Technical Field

[0001] The present invention relates to the field of optical device manufacturing, and particularly to a two-dimensional fiber array with high return loss and a manufacturing method thereof. Background Art

[0002] Fiber optic communication technology is a communication method that uses optical fibers to transmit optical signals and is widely used in fields such as telecommunications, data centers, and fiber to the home. Fiber optic devices are the core components of fiber optic communication technology. Among them, a fiber array (abbreviated as FA) is an important fiber optic device, which is composed of dozens to hundreds of optical fibers combined in a certain arrangement, and can realize the efficient transmission and processing of optical signals; a fiber array is an array formed by installing a bundle of optical fibers or an optical fiber ribbon on the end face of an optical fiber at a specified interval using the end face of the optical fiber.

[0003] The fiber arrays of the prior art usually adopt a 0° plane, that is, the end face of the optical fiber is perpendicular to the optical fiber axis, and the cutting end face of each optical fiber is flat and perpendicular to its respective optical fiber axis; this structure is simple and easy to implement and is suitable for general fiber connection requirements.

[0004] The noise in the fiber array mainly comes from the reflection, scattering, and transmission loss of optical signals; the reflected light may interfere with the original optical signal, resulting in a decrease in signal quality and even damage to the light source. During the transmission of optical signals, due to the end face reflection of the optical fiber or the mismatch of the connector, part of the optical signal is reflected back towards the light source direction, generating return light, and the return light will interfere with the transmission of the original optical signal and reduce the system performance. Due to the impedance mismatch or discontinuity at the fiber connection, part of the optical signal is reflected back towards the light source direction and power loss occurs, that is, return loss; return loss is usually expressed in decibel values, and the larger the value, the less the corresponding return light and the higher the return loss.

[0005] When the fiber array usually adopts a 0° plane, although efficient coupling of the communication optical path can be achieved, since the end face of the optical fiber is perpendicular to the optical fiber axis, as Figure 1 shown, the return light of the incident optical fiber can also enter the optical path of this optical fiber, bringing relatively large noise to the system communication, resulting in a lower return loss and seriously affecting the quality and stability of the system communication.

[0006] In view of this, overcoming the defects of this prior art is an urgent problem to be solved in this technical field. Summary of the Invention

[0007] The technical problem to be solved by the present invention is to provide a two-dimensional optical fiber array with high return loss and a manufacturing method thereof. The purpose is to provide a two-dimensional optical fiber array with high return loss to reduce the return loss of the optical fiber array in the prior art; and to provide a method for angular grinding of a two-dimensional optical fiber array to realize the manufacture of a two-dimensional optical fiber array, improve the return loss of the optical fiber array at low cost, reduce system communication noise, and solve the problem that the return light energy of the incident optical fiber enters the optical path of the optical fiber, bringing relatively large noise to system communication and resulting in low return loss.

[0008] The present invention adopts the following technical solutions:

[0009] In the first aspect, the present invention further provides a two-dimensional optical fiber array with high return loss, including a substrate and multiple optical fibers; the multiple optical fibers are arranged on the substrate in a two-dimensional array form;

[0010] The surface of the substrate is ground with multiple inclined planes, and each inclined plane is inclined at a preset angle relative to a reference plane, so that the end face of each optical fiber is also ground into a preset angle, wherein the plane where the high point of each inclined plane is located is the reference plane.

[0011] In the second aspect, the present invention provides a manufacturing method of a two-dimensional optical fiber array with high return loss for realizing the two-dimensional optical fiber array with high return loss described in the first aspect, including:

[0012] Bring the substrate of the two-dimensional optical fiber array into contact with the first grinding surface of the annular grinding disc at a preset angle;

[0013] Control the annular grinding disc to rotate around the center, and control the two-dimensional optical fiber array to reciprocate along the straight line where the current row of optical fibers is located;

[0014] Grind the surface of the substrate through the first grinding surface so that the end face of the current row of optical fibers is ground into a preset angle, and move the two-dimensional optical fiber array so that the substrate corresponding to the next row of optical fibers is in contact with the annular grinding disc to grind the end face of the next row of optical fibers.

[0015] Further, the annular grinding disc further includes a second grinding surface perpendicular to the first grinding surface, and the manufacturing method further includes:

[0016] Control the reciprocating speed of the ground end of the two-dimensional optical fiber array and the rotation speed of the annular grinding disc so that the shape of the ground end face perfectly fits the first grinding surface and the second grinding surface.

[0017] Further, the grinding of the surface of the substrate through the first grinding surface includes:

[0018] Bring the first grinding surface into close contact with the substrate surface, so that when the two-dimensional optical fiber array reciprocates along the straight line where the current row of optical fibers is located, the substrate surface is opened and the angles of the end faces of the optical fibers are ground to obtain at least one to-be-ground surface corresponding to the current row of optical fibers;

[0019] Bring the first grinding surface into close contact with the slope surface of the at least one to-be-ground surface, and bring the second grinding surface into close contact with the vertical surface of the at least one to-be-ground surface, so that when the two-dimensional optical fiber array reciprocates along the straight line where the current row of optical fibers is located, the slope surface and the vertical surface are ground to obtain at least one inclined surface at a preset angle with respect to the reference surface.

[0020] Further, both the first grinding surface and the second grinding surface of the annular grinding disc are abrasive surfaces with particles;

[0021] The contact surface width between the first grinding surface and the substrate surface is less than or equal to the column pitch of the two-dimensional optical fiber array;

[0022] The thickness of the annular grinding disc is greater than a lower limit value; wherein, the lower limit value is the product of the column pitch and the sine value of the preset angle.

[0023] Further, the annular grinding disc has a multi-stage annular grinding structure;

[0024] The bringing the substrate of the two-dimensional optical fiber array into contact with the first grinding surface of the annular grinding disc at a preset angle further includes:

[0025] The substrate surface of the substrate is in close contact with the first grinding surfaces corresponding to the respective multi-stage annular grinding structures of the annular grinding disc at a preset angle, and one-stage annular grinding structure corresponds to grinding one row of optical fibers.

[0026] Further, the method for manufacturing the two-dimensional optical fiber array with high return loss further includes:

[0027] The substrate surface is ground through the first grinding surfaces corresponding to the respective multi-stage annular grinding structures, so that the end faces of the optical fibers in the corresponding number of rows are ground into a preset angle;

[0028] Move the two-dimensional optical fiber array so that the first grinding surface of each stage of annular grinding structure is in close contact with the substrate surface corresponding to the next row of optical fibers to grind the end faces of the optical fibers in the next row..

[0029] Further, except for the last-stage annular grinding structure, the thickness of each stage of annular grinding structure is equal to a preset thickness value; wherein, the ratio of the preset thickness value to tanθ is: an integer multiple of the distance between adjacent optical fibers to be ground.

[0030] Further, the manufacturing method includes processing one or more stages of rough grinding, fine grinding, and polishing using annular grinding discs with different roughnesses.

[0031] Further, the substrate is made of silicon, glass, or ceramic.

[0032] In a third aspect, the present invention also provides an implementation system for a two-dimensional fiber optic array with high return loss, including the two-dimensional fiber optic array with high return loss as described in the first aspect, and using the manufacturing method of the two-dimensional fiber optic array with high return loss as described in the second aspect to complete the interaction of the two-dimensional fiber optic array with high return loss in the first aspect.

[0033] Different from the prior art, the present invention has at least the following beneficial effects:

[0034] During the optical signal transmission process of the present invention, since the end face of the optical fiber is inclined at a preset angle with respect to the optical fiber input end, even if there is impedance mismatch or discontinuity at the optical fiber connection, resulting in some optical signals being reflected back towards the light source direction, the corresponding return light will not enter the optical path of this optical fiber, greatly reducing the noise brought by the return light to the system communication. Therefore, the return loss of the fiber optic array can be effectively improved, and the quality and stability of the system communication can be enhanced.

[0035] The present invention also provides a manufacturing method for a two-dimensional fiber optic array. Using an annular grinding disc, the end face of the optical fiber is ground to be inclined at a preset angle with respect to the optical fiber input end; by reciprocating and swinging to gradually grind the surface of the substrate of the two-dimensional fiber optic array, the end face of the optical fiber is ground into a preset angle. The manufacturing method is simple and easy to implement, which is beneficial to improving the efficiency and quality of fiber optic device manufacturing, reducing the difficulty and cost of fiber optic device manufacturing, and has strong practicability and broad application prospects. Description of the Drawings

[0036] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following will briefly introduce the drawings required to be used in the embodiments of the present invention. Obviously, the following described drawings are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0037] Figure 1 It is a schematic diagram of a specific example of an optical fiber array of the prior art provided by an embodiment of the present invention;

[0038] Figure 2 It is a schematic diagram of a specific example of a two-dimensional fiber optic array with high return loss provided by an embodiment of the present invention;

[0039] Figure 3 It is a schematic diagram of a specific example of a second two-dimensional fiber optic array with high return loss provided by an embodiment of the present invention;

[0040] Figure 4 It is a schematic diagram of a specific example of the third two-dimensional optical fiber array with high return loss provided by an embodiment of the present invention;

[0041] Figure 5 It is a schematic flowchart of a manufacturing method of a two-dimensional optical fiber array with high return loss provided by an embodiment of the present invention;

[0042] Figure 6 It is a schematic diagram of a specific example of the positional relationship between the first annular grinding disc and the two-dimensional optical fiber array provided by an embodiment of the present invention;

[0043] Figure 7 It is a schematic diagram of a specific example of the positional relationship between the second annular grinding disc and the two-dimensional optical fiber array provided by an embodiment of the present invention;

[0044] Figure 8 It is a schematic diagram of a specific example of grinding the annular grinding disc and the two-dimensional optical fiber array provided by an embodiment of the present invention;

[0045] Figure 9 It is a schematic flowchart of step 30 provided by an embodiment of the present invention;

[0046] Figure 10 It is a schematic diagram of a specific example of the positional relationship between the third annular grinding disc and the two-dimensional optical fiber array provided by an embodiment of the present invention;

[0047] Figure 11 It is a schematic diagram of a specific example of the positional relationship between the third annular grinding disc and the two-dimensional optical fiber array provided by an embodiment of the present invention;

[0048] Figure 12 It is a schematic diagram of a specific example of an annular grinding disc with a multi-stage annular grinding structure provided by an embodiment of the present invention;

[0049] Figure 13 It is a schematic diagram of a specific example of the positional relationship between the multi-stage annular grinding structure and the two-dimensional optical fiber array provided by an embodiment of the present invention;

[0050] Figure 14 It is a schematic flowchart of another manufacturing method of a two-dimensional optical fiber array with high return loss provided by an embodiment of the present invention. Detailed implementation manners

[0051] In order to make the objectives, technical solutions and advantages of the present invention clearer and more understandable, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0052] In order to make the objectives, technical solutions and advantages of the present invention more clearly understood, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0053] Unless the context requires otherwise, throughout the specification and claims, the term "comprising" is to be construed in an open, inclusive sense, i.e., "including, but not limited to". In the description of the specification, the terms "one embodiment", "some embodiments", "exemplary embodiments", "examples", "specific examples", or "some examples", etc. are intended to indicate that specific features, structures, materials, or characteristics related to the embodiment or example are included in at least one embodiment or example of the present disclosure. The schematic representations of the above terms are not necessarily directed to the same embodiment or example. In addition, the specific features, structures, materials, or characteristics may be included in any one or more embodiments or examples in any suitable manner, that is, although they may be carried in the above-mentioned embodiments or examples due to reasons such as the order and position of appearance, but it does not limit that they can be carried by one embodiment or example in a combined manner.

[0054] In the description of the present invention, it should be understood that the orientation or positional relationship indicated by the terms "center", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present disclosure and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation to the present disclosure.

[0055] In the description of the present invention, the terms "first" and "second" are only used for descriptive purposes and cannot be construed as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include one or more of such features. In the description of the embodiments of the present disclosure, unless otherwise stated, the meaning of "a plurality" is two or more. In addition, for example, in the description, for the same type of nouns, the method of adding "A" and "B" at the end is used to describe them as two independent individuals. In this case, the features defined with "A" and "B" are only used for the purpose of distinguishing the same type of individuals and cannot be construed as indicating or implying relative importance or implicitly indicating the number of the indicated technical features.

[0056] In describing some embodiments, the expressions "coupled", "coupling", and "connected" and their derivatives may be used. For example, in describing some embodiments, the term "connected" may be used to indicate that two or more components have direct physical or electrical contact with each other. Another example is that in describing some embodiments, the term "coupled" may be used to indicate that two or more components have direct physical or electrical contact. However, the term "connected" or "coupled" may also mean that two or more components do not have direct contact with each other, but still cooperate or interact with each other, such as "optical path coupling", "wireless connection", etc. The embodiments disclosed herein are not necessarily limited to the content of the present invention.

[0057] In the description of the present invention, the expression "A and / or B" (where A and B are used to formally represent specific feature contents) is involved, and the corresponding expression includes the following three combinations: only A, only B, and the combination of A and B.

[0058] As used in the present invention, "about", "substantially", or "approximately" includes the stated value and the average value within an acceptable deviation range of the specific value, where the acceptable deviation range is determined by those of ordinary skill in the art considering the measurement being discussed and the error associated with the measurement of the specific quantity (i.e., the limitations of the measurement system).

[0059] Example 1:

[0060] To solve the above problems, as Figure 2 and Figure 4 shown, an embodiment of the present invention provides a two-dimensional fiber optic array with high return loss, including a substrate 1 and a plurality of optical fibers 2; the plurality of optical fibers 2 are arranged on the substrate 1 and are arranged in a two-dimensional array form on the substrate 1;

[0061] The surface of the substrate 1 is ground with a plurality of inclined surfaces, and each inclined surface is inclined at a preset angle (such as Figure 4 shown by θ in) relative to a reference plane, so that the end face of each optical fiber 2 is also ground into a preset angle, where the heights of the high points of each inclined surface are the same, and the plane where the high points of each inclined surface are located is the reference plane.

[0062] Among them, the preset angle is selected by those skilled in the art according to the specific usage scenario. In an optional embodiment, the preset angle can be 8°.

[0063] In an actual usage scenario, as Figure 3 shown, a two-dimensional fiber optic array of M rows and N columns is one of the most commonly used forms. The substrate 1 of the two-dimensional fiber optic array of the embodiment of the present invention is provided with M rows and N columns of optical fibers 2. As Figure 4As shown, the inclined surfaces of multiple substrates are arranged in a zigzag pattern; the reference plane is perpendicular to the optical fiber axis of optical fiber 2 in the two-dimensional optical fiber array, and the end face of optical fiber 2 is inclined at a preset angle with respect to the reference plane.

[0064] In one embodiment, multiple optical fibers 2 and the substrate 1 are bonded to achieve an arrangement in a two-dimensional array on the substrate 1.

[0065] In the process of optical signal transmission of the present invention, since the end face of the optical fiber is inclined at a preset angle with respect to the optical fiber input end, even if there is impedance mismatch or discontinuity at the optical fiber connection, resulting in partial optical signal reflection back to the light source direction, the corresponding return light will not enter the optical path of this optical fiber, greatly reducing the noise brought by the return light to system communication. Therefore, the return loss of the optical fiber array can be effectively improved, and the quality and stability of system communication can be improved.

[0066] In the embodiment of the present invention, the inclined surface grinding method is adopted to optimize the end face angle of the optical fiber to reduce the return light, effectively improve the return loss of the two-dimensional optical fiber array, and thus reduce the noise. Specifically, the optical fiber is composed of a core, a cladding, and a coating layer; the core is the central part of the optical fiber and is the channel for optical signal transmission; it is used to ensure that the optical signal can be efficiently transmitted in the core. The cladding is a structure that wraps around the core and plays a role in protecting the core; the refractive index of the cladding is lower than that of the core, so that total reflection occurs at the interface between the core and the cladding, thereby restricting the optical signal to be transmitted in the core and reducing the loss of light. The coating layer is a protective layer wrapped outside the cladding and is usually made of plastic or other materials, which is used to protect the optical fiber from physical damage and environmental influences. Since the inclined surface guides the reflected light into the cladding of the optical fiber instead of directly returning to the core, reducing the interference of the reflected light on the signal, grinding the end face of the optical fiber into an inclined surface with a preset angle can significantly improve the return loss.

[0067] In one embodiment, when the preset angle is 8°, since the 8° angle is close to the critical angle of the numerical aperture (NA) of the optical fiber, the reflected light cannot enter the core again, thereby greatly improving the return loss of the optical fiber array and optimizing the performance of the optical fiber communication system.

[0068] In one embodiment, the return loss of the two-dimensional optical fiber array in the prior art is 15 dB. Using the two-dimensional optical fiber array with high return loss of the embodiment of the present invention, when the preset angle is 8°, the return loss of the corresponding two-dimensional optical fiber array can be increased to 60 dB.

[0069] Example 2:

[0070] In order to obtain the two-dimensional optical fiber array with high return loss of Embodiment 1, as Figure 5As shown in the figure, an embodiment of the present invention provides a method for manufacturing a two-dimensional fiber array with high return loss, including:

[0071] Step 10: Bring the substrate of the two-dimensional fiber array into contact with the first grinding surface of the annular grinding disc at a preset angle.

[0072] As Figure 6 shown in the figure, an embodiment of the present invention provides an annular grinding disc. The annular grinding disc is used to grind the substrate of the two-dimensional fiber array so that the end face of the optical fiber is inclined at a preset angle with respect to the reference plane, and the surface of the substrate where the end face is located is also inclined at a preset angle with respect to the reference plane; wherein, the first grinding surface is Figure 6 the upper surface of the annular grinding disc in

[0073] Before grinding the substrate, the surface of the substrate is flat, that is, like the reference plane in Figure 4 the figure. An embodiment of the present invention grinds this surface to obtain a plurality of inclined surfaces at a preset angle on this surface. During the process of grinding the inclined surface, the end face of the optical fiber is also ground to be inclined at a preset angle.

[0074] As Figure 7 shown in the figure, when grinding the substrate, in order to grind it into an inclined surface at a preset angle, it is first necessary to bring the substrate into contact with the first grinding surface at a preset angle.

[0075] Step 20: Control the annular grinding disc to rotate around the center, and control the two-dimensional fiber array to reciprocally swing along the straight line where the fibers in the current row are located.

[0076] As Figure 8 shown in the figure, during grinding, the two-dimensional fiber array to be ground is clamped and inclined at a preset angle and in contact with the first grinding surface. At the same time, the annular grinding disc makes a circular motion around the center and makes a linear reciprocating swing in the direction shown in Figure 6 the figure to grind the end faces of a row of fibers in the fiber array.

[0077] Step 30: Grind the surface of the substrate through the first grinding surface so that the end faces of the fibers in the current row are ground into a preset angle, and move the two-dimensional fiber array so that the substrate corresponding to the next row of fibers comes into contact with the annular grinding disc to grind the end faces of the next row of fibers.

[0078] Among them, the substrate surface is the surface of the substrate. The substrate surface in the embodiment of the present invention refers to the surface of the substrate where the end face of the optical fiber is located.

[0079] As Figure 7 and Figure 10As shown, by controlling the step-by-step movement of the two-dimensional optical fiber array to be ground, the end faces of the optical fibers and the corresponding substrate surfaces are ground row by row, making the substrate surface serrated, and finally grinding the end faces of the optical fibers to be inclined at a preset angle. In one embodiment, the grinding amount for grinding each row of surfaces is set through parameters; since when the two-dimensional optical fiber array grinding is completed, the corresponding surface changes from a reference surface to multiple rows of inclined surfaces, only when the grinding amounts are consistent and the high points of each angle of each row of inclined surfaces are consistent can it be reflected that the end faces of each row of optical fibers are all inclined at a unified preset angle, and then the optical path coupling of the end faces can be carried out normally.

[0080] The present invention provides a manufacturing method for a two-dimensional optical fiber array, which uses an annular grinding disc to grind the end face of the optical fiber to be inclined at a preset angle with respect to the optical fiber input end; by reciprocating and swinging to grind the surface of the substrate of the two-dimensional optical fiber array step by step, the end face of the optical fiber is ground into a preset angle. The manufacturing method is simple and easy to implement, which is beneficial to improving the efficiency and quality of optical fiber device manufacturing, reducing the difficulty and cost of optical fiber device manufacturing, and has strong practicability and broad application prospects.

[0081] To further illustrate the manufacturing method of the two-dimensional optical fiber array with high return loss in the embodiments of the present invention, the embodiments of the present invention provide a specific example as follows:

[0082] Wherein, a plurality of optical fibers are arranged on the substrate, and the end faces of the optical fibers are flush with the substrate surface of the substrate. In an optional embodiment, the material of the substrate is silicon, glass or ceramic. The manufacturing method in the embodiments of the present invention uses a substrate made of silicon or glass material. This material has good optical fiber grinding performance, is easy to obtain and has a low cost, which is convenient for the processing and manufacturing of optical fibers and is beneficial to reducing the manufacturing cost of optical fiber devices.

[0083] In an optional embodiment, the thickness range of the substrate can be 3 mm to 6 mm; the outer diameter of the annular grinding disc is 50 mm, the inner diameter is 48 mm, and the thickness is 1 mm.

[0084] To illustrate the grinding process, as Figure 9 shown, in step 30, the grinding of the substrate surface by the first grinding surface includes:

[0085] Step 301: Make the first grinding surface in close contact with the substrate surface, so as to open the substrate surface and grind the angle of the end face of the optical fiber when the two-dimensional optical fiber array reciprocates and swings along the straight line where the current row of optical fibers is located, and obtain at least one surface to be ground corresponding to the current row of optical fibers.

[0086] Since before grinding the substrate, the surface of the substrate is as Figure 4The middle reference plane, so when opening the surface, it is necessary to make the end face of the optical fiber fit with the first grinding surface. By rotating the annular grinding disc and the relative movement of the optical fiber, the material of the end face of the optical fiber is gradually removed to form the required inclined plane angle on the surface of the substrate. Among them, the surface to be ground is the surface of the substrate corresponding to the current row of optical fibers to be ground.

[0087] To further illustrate the grinding process, the relevant features of the annular grinding disc and the substrate are described first:

[0088] As Figure 10 shown, the contact surface width between the first grinding surface and the substrate surface is less than or equal to the column pitch of the two-dimensional optical fiber array.

[0089] As Figure 11 shown, since the end face of the optical fiber needs to be in the center of the inclined plane, the column pitch of the two-dimensional optical fiber array is the pitch between each row of M rows of optical fibers. The contact surface width between the first grinding surface and the substrate surface is the width of their contact surface; the contact surface width needs to make the grinding range of the first grinding surface at least include the end face of the current row of optical fibers. In an optional embodiment, the contact surface width is equal to the column pitch.

[0090] As Figure 11 shown, the thickness of the annular grinding disc is greater than the lower limit value of the thickness; wherein, the lower limit value of the thickness is the product of the column pitch and the sine value of the preset angle.

[0091] For example, when the column pitch is a, the lower limit value of the thickness is asinθ.

[0092] To ensure the performance of the end face of the optical fiber after grinding, the manufacturing method includes processing one or more stages of rough grinding, fine grinding and polishing using annular grinding discs with different roughnesses.

[0093] In one embodiment, by replacing the annular grinding discs with different roughnesses and controlling the movement of the optical fiber array to be ground, moving step by step, each row of the M rows of the two-dimensional optical fiber array is opened, rough ground, fine ground, until polishing is completed; through cold processing such as rough grinding, fine grinding and polishing, the surface roughness of the end face of the optical fiber is reduced to an extremely low level, ensuring the surface quality of the end face of the optical fiber and the angle and shape of the end face, so as to reduce the scattering and reflection of the optical signal at the end face of the optical fiber, thereby improving the transmission efficiency of the optical signal, significantly improving the return loss, ensuring the reliability and performance of the optical fiber connection, effectively reducing the attenuation and distortion of the optical signal, and further making the optical fiber surface achieve a lossless light transmission effect.

[0094] In an optional embodiment, an annular grinding disc with a roughness of 30 microns can be used to open the surface of the substrate (that is, grind the surface into a row of inclined planes).

[0095] Step 302: Make the first grinding surface closely contact the slope surface of the at least one surface to be ground, and make the second grinding surface closely contact the vertical surface of the at least one surface to be ground, so as to grind the slope surface and the vertical surface when the two-dimensional optical fiber array reciprocally swings along the straight line where the current row of optical fibers is located, and obtain at least one inclined surface that forms a preset angle with the reference surface.

[0096] After the surface opening is performed, the surface to be ground is divided into a vertical surface and a corresponding slope surface. As Figure 7 shown, when grinding the current row of optical fibers on the far left, the slope surface is the end surface of the optical fiber and the surface of the substrate where it is located, and the vertical surface is parallel to the optical fiber axis.

[0097] As Figure 8 shown, the annular grinding disc further includes a second grinding surface perpendicular to the first grinding surface, and both the first grinding surface and the second grinding surface of the annular grinding disc are grinding surfaces with particles.

[0098] After the surface opening has been completed, it is necessary to make the end surface of the optical fiber fit with the first grinding surface and the second grinding surface. The second grinding surface is used to provide support for the annular grinding disc to ensure that the optical fiber will not shift or tilt during the grinding process, thereby ensuring the accuracy of the grinding angle.

[0099] In an optional embodiment, after finishing the polishing of the current row of optical fibers, move the two-dimensional optical fiber array from the current row to the next row, and repeat Step 301 and Step 302 until the M rows of the two-dimensional optical fiber array are ground one by one. Then replace the grinding discs with different roughnesses, and grind the M rows of the two-dimensional optical fiber array one by one until the inclined surfaces and end surfaces of each row of the two-dimensional optical fiber array are all polished.

[0100] In an optional embodiment, an annular grinding disc with a roughness of 9 microns can be used to rough grind the substrate; an annular grinding disc with a roughness of 5 microns can be used to fine grind the substrate; an annular grinding disc with a roughness of 1 micron can be used to polish the substrate.

[0101] During the above grinding process, the reciprocating speed of the ground end of the two-dimensional optical fiber array and the rotation speed of the annular grinding disc are both controlled to make the shape of the ground end surface perfectly fit with the first grinding surface and the second grinding surface.

[0102] The embodiment of the present invention uses an annular grinding disc, and by clamping the optical fiber array to be ground to make a linear reciprocating swing, the end surfaces of a row of optical fibers in the optical fiber array are ground; by controlling the movement of the optical fiber array to be ground and moving it step by step, the end surfaces of each row of optical fibers are inclined at a preset angle; the manufacturing method of the embodiment of the present invention improves the manufacturing efficiency of the two-dimensional optical fiber array and reduces the manufacturing cost.

[0103] It should be noted that the manufacturing method of the two-dimensional optical fiber array with high return loss in the embodiments of the present invention is carried out under normal temperature and pressure, without the need for special equipment and tools, only a ring-shaped grinding disc and equipment for controlling the reciprocating speed of the ground end are required.

[0104] Example 3:

[0105] This embodiment is an optimized solution of Embodiment 2, which is used to further improve the manufacturing efficiency of the manufacturing method of the two-dimensional optical fiber array. To further illustrate the manufacturing method of the two-dimensional optical fiber array with high return loss in the embodiments of the present invention, a specific example is provided in the embodiments of the present invention as follows:

[0106] This embodiment provides an optimized solution of a ring-shaped grinding disc. First, the ring-shaped grinding disc of this embodiment will be described below:

[0107] As Figure 12 shown, the ring-shaped grinding disc has multiple levels of ring-shaped grinding structures; starting from the ring-shaped grinding structure with the smallest inner diameter, the corresponding inner diameters of each level of ring-shaped grinding structures increase gradually, and the corresponding outer diameters also increase gradually; among them, the inner diameter, outer diameter, and thickness of each level of ring-shaped grinding structure are selected by those skilled in the art according to specific usage scenarios. As Figure 13 shown, except for the last level of ring-shaped grinding structure, the thickness of each level of ring-shaped grinding structure is equal to a preset thickness value; among them, the ratio of the preset thickness value to tanθ is: an integer multiple of the distance between adjacent optical fibers to be ground, Figure 13 in which, in the order of increasing inner diameter, the preset thickness value of the first-level ring-shaped grinding structure is b, and the adjacent optical fibers to be ground are ground by the first-level ring-shaped grinding structure and the second-level ring-shaped grinding structure respectively, and the integer multiple of the distance between the adjacent optical fibers to be ground is c; among them, the integer multiple of the distance is centered on the midpoint of the distance between two optical fibers.

[0108] When using the ring-shaped grinding disc of this embodiment to grind the substrate, as Figure 14 shown, step 10 further includes:

[0109] Step 40: The substrate surface of the substrate is in close contact with the first grinding surface corresponding to each level of ring-shaped grinding structure of the ring-shaped grinding disc at a preset angle, and one level of ring-shaped grinding structure corresponds to grinding one row of optical fibers.

[0110] For example, as Figure 13 shown, when the ring-shaped grinding disc has three levels of ring-shaped grinding structures, the ring-shaped grinding disc of this embodiment is used to grind the positions of three rows of optical fibers on the substrate surface at the same time. During grinding, it is first necessary to make the upper surface of the three-level ring-shaped grinding structure (i.e., the first grinding surface corresponding to each level of ring-shaped grinding structure) in close contact with the reference surface at a preset angle.

[0111] After the step 10, the method further includes:

[0112] Step 50: Grind the surface of the substrate through the first grinding surfaces corresponding to the respective annular grinding structures, so that the end faces of the optical fibers in the corresponding rows are ground into a preset angle.

[0113] For example, as Figure 13 shown, grind the end faces of the optical fibers in three rows simultaneously, and each time control the two-dimensional optical fiber array to reciprocally swing along the straight line where the three rows of optical fibers are located, so as to grind the surfaces at the positions where the three rows of optical fibers are located.

[0114] Step 60: Move the two-dimensional optical fiber array so that the first grinding surface of each level of annular grinding structure is in close contact with the surface of the substrate corresponding to the next row of optical fibers, so as to grind the end faces of the next row of optical fibers.

[0115] In an alternative embodiment, after polishing the current three rows of optical fibers, move the two-dimensional optical fiber array from the positions where the current three rows of optical fibers are located to the positions where the corresponding next row of optical fibers are located until the M rows of the two-dimensional optical fiber array are ground one by one. For example, move the two-dimensional optical fiber array from the positions where the first row of optical fibers are located to the positions where the second row of optical fibers are located, and thus it can be realized to move the two-dimensional optical fiber array from the positions where the fifth row of optical fibers are located to the positions where the sixth row of optical fibers are located.

[0116] The other manufacturing steps are the same as those in Embodiment 2, and will not be elaborated here.

[0117] It should be noted that, regarding the information interaction, execution process, etc. between the modules and units in the above-mentioned device and system, since they are based on the same concept as the method embodiment of the present invention, the specific content can be referred to the description in the method embodiment of the present invention, and will not be elaborated here.

[0118] Those of ordinary skill in the art can understand that all or part of the steps in the various methods of the embodiments can be completed by instructing relevant hardware through a program, and the program can be stored in a computer-readable storage medium. The storage medium can include: read-only memory (ROM, Read Only Memory), random access memory (RAM, Random Access Memory), magnetic disk or optical disk, etc.

[0119] The above are only the preferred embodiments of the present invention, and are not intended to limit the present invention. Any modifications, equivalent replacements, and improvements made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A two-dimensional optical fiber array with high return loss, characterized in that: It comprises a substrate and a plurality of optical fibers; the plurality of optical fibers are disposed on the substrate and arranged in a two-dimensional array on the substrate; The surface of the substrate is ground with multiple bevels, each of which is inclined at a preset angle relative to a reference plane, so that the end face of each optical fiber is also ground to a preset angle, wherein the surface where the high point of each bevel is located is the reference plane.

2. A method for manufacturing a two-dimensional optical fiber array with high return loss, characterized in that: include: The substrate of the two-dimensional optical fiber array is brought into contact with the first grinding surface of the annular grinding disk at a preset angle; Controlling the annular grinding disc to rotate around the center of the circle, and controlling the two-dimensional optical fiber array to perform reciprocating swinging motion along the straight line where the current row of optical fibers is located; The first grinding surface is used to grind the substrate surface so that the end face of the current row of optical fibers is grinded to a preset angle, and the two-dimensional optical fiber array is moved so that the substrate corresponding to the next row of optical fibers contacts the annular grinding disk to grind the end face of the next row of optical fibers.

3. The method for manufacturing a two-dimensional optical fiber array with high return loss according to claim 2, characterized in that: The annular grinding disc further includes a second grinding surface perpendicular to the first grinding surface, and the manufacturing method further includes: The reciprocating speed of the polished end of the two-dimensional optical fiber array and the rotation speed of the annular polishing disk are controlled so that the shape of the polished end surface is perfectly matched with the first polishing surface and the second polishing surface.

4. The method for manufacturing a two-dimensional optical fiber array with high return loss according to claim 3, characterized in that: The grinding of the substrate surface by the first grinding surface comprises: The first grinding surface is brought into close contact with the substrate surface, so that when the two-dimensional optical fiber array makes a reciprocating swinging motion along the straight line where the current row of optical fibers is located, the substrate surface is opened and the angle of the end face of the optical fiber is ground to obtain at least one to-be-ground surface corresponding to the current row of optical fibers; The first grinding surface is brought into close contact with the slope surface of the at least one surface to be ground, and the second grinding surface is brought into close contact with the vertical surface of the at least one surface to be ground, so that when the two-dimensional optical fiber array performs reciprocating swinging motion along the straight line where the current row of optical fibers is located, the slope surface and the vertical surface are ground to obtain at least one inclined surface with a preset angle to the reference surface.

5. The method for manufacturing a two-dimensional optical fiber array with high return loss according to claim 3, characterized in that: The first grinding surface and the second grinding surface of the annular grinding disc are both grinding surfaces with particles; The contact surface width between the first polishing surface and the substrate surface is less than or equal to the column spacing of the two-dimensional optical fiber array; The thickness of the annular grinding disc is greater than a lower limit value of the thickness; wherein the lower limit value of the thickness is the product of the row spacing and the sine value of the preset angle.

6. The method for manufacturing a two-dimensional optical fiber array with high return loss according to claim 3, characterized in that: The annular grinding disc has a multi-stage annular grinding structure; The step of bringing the substrate of the two-dimensional optical fiber array into contact with the first grinding surface of the annular grinding disk at a preset angle further comprises: The substrate surface of the substrate is in close contact with the first grinding surfaces corresponding to the various levels of annular grinding structures of the annular grinding disc at a preset angle, and the first level of the annular grinding structure grinds a row of optical fibers correspondingly.

7. The method for manufacturing a two-dimensional optical fiber array with high return loss according to claim 6, characterized in that: The method for manufacturing the two-dimensional optical fiber array with high return loss also includes: The substrate surface is ground by the first grinding surfaces corresponding to the respective levels of the annular grinding structures, so that the end faces of the corresponding number of rows of optical fibers are ground to a preset angle; The two-dimensional optical fiber array is moved so that the first grinding surface of each level of the annular grinding structure is in close contact with the substrate surface corresponding to the next row of optical fibers, so as to grind the end faces of the next row of optical fibers.

8. The method for manufacturing a two-dimensional optical fiber array with high return loss according to claim 6, characterized in that: Except for the last annular grinding structure, the thickness of each annular grinding structure is equal to a preset thickness value; wherein the ratio of the preset thickness value to tanθ is an integer multiple of the spacing between adjacent polished optical fibers.

9. The method for manufacturing a two-dimensional optical fiber array with high return loss according to any one of claims 2 to 8, characterized in that: The manufacturing method comprises using annular grinding discs with different roughnesses to perform one or more stages of rough grinding, fine grinding and polishing.

10. The method for manufacturing a two-dimensional optical fiber array with high return loss according to any one of claims 2 to 8, characterized in that: The substrate is made of silicon, glass or ceramic.

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