Optical fiber array unit with guide member

Abstract

Optical fiber array unit assemblies and methods of making the same are provided herein. An optical fiber array unit (100) includes a first group of optical fibers (110), a first guide member (112A), and a second guide member (112B). The fiber optic array unit (100) includes a fiber optic array structure (102) having a surface (101) that defines a first groove (104A) and a second groove (104B). The surface (101) defines a first region (107) between the first groove and the second groove, wherein the first region is disposed without any groove. The first guide member is received in the first groove to assist in positioning the first guide member relative to the fiber array structure. The second guide member is received in the second groove to assist in positioning the second guide member relative to the fiber array structure. Each optical fiber (110) of the first set of optical fibers is positioned between the first guide member (112A) and the second guide member (112A).

Description

[0001] Priority Application

[0002] This application claims the priority benefit of U.S. Provisional Application No. 63 / 428,136, filed on November 28, 2022, the content of which is relied upon herein and incorporated herein by reference in its entirety. Technical Field

[0003] Embodiments of the present invention generally relate to an optical fiber array unit having guiding members, and more particularly, to an optical fiber array unit capable of achieving passive alignment of optical fibers without grooves for individual optical fibers. Background Art

[0004] Substrates have been provided that are configured to position optical fibers such that the optical fibers can form optical interconnects. Some of these substrates have grooves for each optical fiber in an attempt to control the position of each optical fiber, which results in a more complex and costly manufacture of the substrate. Other substrates are provided without any grooves, increasing the difficulty of optical fiber alignment and the risk of inaccurate optical fiber positioning, which may result in, for example, signal loss during connection, wasted time during assembly, and / or waste of the entire optical fiber array. Summary of the Invention

[0005] Embodiments of the present invention relate to an optical fiber array unit having two or more guiding members. The optical fiber array unit may include an optical fiber array structure having grooves, and the grooves may be configured to receive the guiding members. The optical fiber array unit may be provided without grooves for each of the individual optical fibers, and the optical fibers may be positioned between the guiding members. The guiding members may act as sidewalls to assist in positioning the optical fibers, thereby achieving effective passive alignment of the optical fibers. When the optical fibers are properly positioned, the optical fibers may be fixed relative to the optical fiber array structure to retain the optical fibers in place. Since the optical fiber array structure is provided without grooves for each optical fiber, the optical fiber array structure can be manufactured at a lower manufacturing cost while still allowing the optical fibers to be properly positioned.

[0006] Dummy optical fibers may also be utilized to effectively control the position of the optical fibers, and the dummy optical fibers may enable the optical fiber array unit to more easily adapt to various usage scenarios. In some embodiments, a single optical fiber layer may be provided, but multiple optical fiber layers may be vertically stacked on the optical fiber array structure. In the case where multiple optical fiber layers are provided in the optical fiber array unit, the layers may be stacked in a staggered manner, thereby allowing the optical fiber array unit to have a high optical fiber density. Additionally, fasteners may be utilized to assist in positioning the guiding members and / or the optical fibers. In some embodiments, multiple fasteners may be used to manufacture the optical fiber array unit, where different fasteners are utilized to position the guiding members, position the first optical fiber layer, and / or position one or more additional optical fiber layers. However, when manufacturing the optical fiber array unit, the same fasteners may be utilized to perform multiple tasks.

[0007] In an exemplary embodiment, an optical fiber array unit is provided that includes a first set of optical fibers, a first guiding member, and a second guiding member, as well as an optical fiber array structure having a surface. The surface of the optical fiber array structure defines a first groove and a second groove, where the surface defines a first region between the first groove and the second groove. The first region is provided without any grooves. Additionally, the first guiding member is at least partially received in the first groove to assist in positioning the first guiding member relative to the optical fiber array structure, and the second guiding member is at least partially received in the second groove to assist in positioning the second guiding member relative to the optical fiber array structure. Each optical fiber in the first set of optical fibers is positioned between the first guiding member and the second guiding member.

[0008] In some embodiments, the optical fiber array unit may further include a second set of optical fibers. The first set of optical fibers may be vertically positioned between the first region and the second set of optical fibers. Each optical fiber in the second set of optical fibers may contact another optical fiber in the first set of optical fibers. Additionally, in some embodiments, the optical fibers in the second set of optical fibers may be positioned such that they contact two optical fibers in the first set of optical fibers. Further, in some embodiments, the first set of optical fibers and the second set of optical fibers may be stacked in an interleaved manner.

[0009] In some embodiments, the first set of optical fibers may be fixed to the first region. Additionally, in some embodiments, the first set of optical fibers may be fixed to the first region by laser welding or by an adhesive.

[0010] In some embodiments, the optical fiber array unit may further include a first set of one or more dummy optical fibers and a second set of one or more dummy optical fibers. The first set of one or more dummy optical fibers and the second set of one or more dummy optical fibers may contact the first region. The first dummy optical fiber in the first set of one or more dummy optical fibers may contact the first guiding member. The first dummy optical fiber or the second dummy optical fiber in the first set of one or more dummy optical fibers may contact the first optical fiber in the first set of optical fibers, the first dummy optical fiber in the second set of one or more dummy optical fibers may contact the second guiding member, and the first dummy optical fiber or the second dummy optical fiber in the second set of one or more dummy optical fibers may contact the second optical fiber in the first set of optical fibers. The first optical fiber in the first set of optical fibers may be positioned at a first end of the first set of optical fibers, the second optical fiber in the first set of optical fibers may be positioned at a second end of the first set of optical fibers, and the second end of the first set of optical fibers may be opposite to the first end of the first set of optical fibers.

[0011] In some embodiments, both the first groove and the second groove can be V-shaped grooves. In some embodiments, the first region can define a flat plane. In some embodiments, the first guiding member and the second guiding member can be at least one of a dowel pin, an optical fiber, or a dummy optical fiber. Additionally, in some embodiments, the first guiding member can define a first guiding member cross-sectional area, the optical fibers in the first group of optical fibers can define an optical fiber cross-sectional area, and the first guiding member cross-sectional area can be greater than the optical fiber cross-sectional area. In some embodiments, the first group of optical fibers, the first guiding member, and the second guiding member can each have a circular cross-section.

[0012] In some embodiments, the first group of optical fibers can be positioned by applying a force to the first group of optical fibers through a first fastener. Additionally, in some embodiments, the first fastener can define a first groove and a second groove, the first groove can be configured to at least partially receive the first guiding member, and the second groove can be configured to at least partially receive the second guiding member. Further, the first fastener can define a plurality of grooves positioned between the first groove and the second groove, and each of the plurality of grooves can be configured to at least partially receive an optical fiber in the first group of optical fibers. In some embodiments, the first fastener can define a plurality of grooves, and each of the plurality of grooves can be configured to at least partially receive an optical fiber in the first group of optical fibers. Additionally, in some embodiments, after positioning the first group of optical fibers, the first fastener can be fixed relative to the fiber array structure.

[0013] In some embodiments, the first fastener can be removed after positioning the first group of optical fibers. Additionally, in some embodiments, the fiber array unit can further include a second group of optical fibers. The first group of optical fibers can be vertically positioned between the first region and the second group of optical fibers, each optical fiber in the second group of optical fibers can contact the first group of optical fibers, and the second group of optical fibers can be positioned against the first group of optical fibers by applying a force to the second group of optical fibers through the first fastener. Additionally, in some embodiments, the fiber array unit can further include a second group of optical fibers. The first group of optical fibers can be vertically positioned between the first region and the second group of optical fibers, each optical fiber in the second group of optical fibers can contact the first group of optical fibers, and the second group of optical fibers can be positioned against the first group of optical fibers by applying a force to the second group of optical fibers through a second fastener.

[0014] In another example embodiment, a method of manufacturing an optical fiber array unit is provided. The method includes providing a first set of optical fibers, a first guiding member, a second guiding member, and an optical fiber array structure. The optical fiber array structure has a surface, where the surface defines a first groove and a second groove. The surface also defines a first region between the first groove and the second groove, and the first region is provided without any grooves. The method further includes: positioning the first guiding member in the first groove; positioning the second guiding member in the second groove; positioning the first set of optical fibers such that each optical fiber in the first set of optical fibers contacts the first region to be positioned between the first guiding member and the second guiding member; and fixing the first set of optical fibers relative to the optical fiber array structure.

[0015] In some embodiments, the first set of optical fibers may be fixed relative to the optical fiber array structure by laser welding or by an adhesive. Additionally, in some embodiments, a first fastener may be used to assist in positioning the first guiding member in the first groove and to assist in positioning the second guiding member in the second groove. In some embodiments, the method may further include: providing a first fastener; and positioning the first set of optical fibers by applying a force to the first set of optical fibers through the first fastener. Further, in some embodiments, the method may further include: providing a second set of optical fibers; positioning the second set of optical fibers such that the first set of optical fibers is vertically positioned between the first region and the second set of optical fibers; and fixing the second set of optical fibers relative to the optical fiber array structure.

[0016] In another example embodiment, an optical fiber array unit is provided, the optical fiber array unit having a first set of optical fibers, a first guiding member, a second guiding member, and an optical fiber array structure. The optical fiber array structure has a surface, and the surface is provided without any grooves. The first guiding member is positioned at a first position on the surface, the second guiding member is positioned at a second position on the surface, and each optical fiber in the first set of optical fibers is positioned between the first guiding member and the second guiding member.

[0017] In some embodiments, the first guiding member may be positioned at the first position by applying a force to the first guiding member through a first fastener. The first fastener may define a first groove, and the first groove may be configured to at least partially receive the first guiding member to assist in positioning the first guiding member at the first position. The second guiding member may be positioned at the second position by applying a force to the second guiding member through the first fastener. The first fastener may define a second groove, and the second groove may be configured to at least partially receive the second guiding member to assist in positioning the second guiding member at the second position. Description of the Drawings

[0018] The present invention has been described in general terms above, and now reference will be made to the drawings, which are not drawn to scale and in which:

[0019] Figure 1A is a perspective view showing an exemplary fiber optic array unit according to some embodiments discussed herein;

[0020] Figure 1B is showing according to some embodiments discussed herein Figure 1A a front view of the fiber optic array unit;

[0021] Figure 1C is showing according to some embodiments discussed herein Figure 1A an enhanced front view of the fiber optic array unit, where an adhesive is used to fix the optical fibers to the fiber optic array structure of the fiber optic array unit;

[0022] Figure 1D is showing according to some embodiments discussed herein Figure 1A an enhanced front view of the fiber optic array unit, where laser welding is used to fix the optical fibers to the fiber optic array structure of the fiber optic array unit;

[0023] Figure 2A is a perspective view showing a first exemplary fastener for forming an exemplary fiber optic array unit according to some embodiments discussed herein;

[0024] Figure 2B is a perspective view showing an exemplary fiber optic array structure according to some embodiments discussed herein, where a guiding member is positioned in a groove of the fiber optic array structure;

[0025] Figure 2C is a perspective view showing a second exemplary fastener for positioning optical fibers according to some embodiments discussed herein;

[0026] Figure 3A is a perspective view showing an exemplary fiber optic array unit according to some embodiments discussed herein, where the optical fibers extend beyond the front edge of the fiber optic array structure;

[0027] Figure 3B is showing according to some embodiments discussed herein Figure 3A a side view of the exemplary fiber optic array unit;

[0028] Figure 3C is a perspective view showing an exemplary fiber optic array unit according to some embodiments discussed herein, where the guiding member extends beyond the front edge of the fiber optic array structure;

[0029] Figure 3D is a perspective view showing an exemplary fiber optic array unit according to some embodiments discussed herein, where the guiding member and the optical fibers extend beyond the front edge of the fiber optic array structure;

[0030] Figure 4AIs a perspective view of an exemplary fiber optic array unit using dummy fibers according to some embodiments discussed herein;

[0031] Figure 4B Is a front view of a fiber optic array unit according to some embodiments discussed herein Figure 4A ;

[0032] Figure 5A Is a perspective view of another exemplary fiber optic array unit according to some embodiments discussed herein, wherein there is a space between the guiding member and the optical fibers;

[0033] Figure 5B Is a perspective view of an exemplary fastener for forming a fiber optic array unit according to some embodiments discussed herein Figure 5A ;

[0034] Figure 5C Is a front view of a fastener and a fiber optic array unit according to some embodiments discussed herein Figure 5B ;

[0035] Figure 5D Is an enhanced front view of a fastener and a fiber optic array unit according to some embodiments discussed herein Figure 5C ;

[0036] Figure 6A Is a perspective view of another exemplary fiber optic array unit according to some embodiments discussed herein, wherein there is a space between the optical fibers;

[0037] Figure 6B Is a perspective view of a fiber optic array unit according to some embodiments discussed herein Figure 6A wherein an exemplary fastener is used to assist in forming the fiber optic array unit;

[0038] Figure 6C Is a front view of a fiber optic array unit and a fastener according to some embodiments discussed herein Figure 6B ;

[0039] Figure 7A Is a perspective view of another exemplary fiber optic array unit according to some embodiments discussed herein, wherein dummy fibers are used and wherein the optical fibers are stacked in multiple layers;

[0040] Figure 7B Is a front view of a fiber optic array unit according to some embodiments discussed herein Figure 7A ;

[0041] Figure 7C Is a perspective view of an exemplary device for assisting in positioning according to some embodiments discussed herein Figure 7AFront view of the first example fastener of the first optical fiber layer of the optical fiber array unit;

[0042] Figure 7D Is a front view showing a second example fastener of the second optical fiber layer of an optical fiber array unit for assisting in positioning according to some embodiments discussed herein; Figure 7A Front view of the second example fastener of the second optical fiber layer of the optical fiber array unit for assisting in positioning;

[0043] Figure 8A Is a front view showing another example optical fiber array unit according to some embodiments discussed herein, where the optical fibers are stacked in multiple layers and there is a space between the optical fibers and the guiding member;

[0044] Figure 8B Is a perspective view showing an optical fiber array unit according to some embodiments discussed herein; Figure 8A Perspective view of the optical fiber array unit;

[0045] Figure 8C Is a front view showing a first example fastener of the first optical fiber layer of an optical fiber array unit for assisting in positioning according to some embodiments discussed herein; Figure 8A Front view of the first example fastener of the first optical fiber layer of the optical fiber array unit for assisting in positioning;

[0046] Figure 8D Is a front view showing a second example fastener of the second optical fiber layer of an optical fiber array unit for assisting in positioning according to some embodiments discussed herein; Figure 8A Front view of the second example fastener of the second optical fiber layer of the optical fiber array unit for assisting in positioning;

[0047] Figure 9A Is a perspective view showing another example optical fiber array unit using three guiding members according to some embodiments discussed herein;

[0048] Figure 9B Is a perspective view showing an example fastener for assisting in forming an optical fiber array unit according to some embodiments discussed herein; Figure 9A Perspective view of the example fastener of the optical fiber array unit for assisting in forming;

[0049] Figure 9C Is a front view showing a fastener and an optical fiber array unit according to some embodiments discussed herein; Figure 9B Front view of the fastener and the optical fiber array unit;

[0050] Figure 10 Is a perspective view showing an example optical fiber array unit according to some embodiments discussed herein, where the optical fibers are spliced together;

[0051] Figure 11 Is a flowchart showing an example method of manufacturing an optical fiber array unit according to some embodiments discussed herein;

[0052] Figure 12is a flowchart showing an example method of manufacturing a fiber optic array unit according to some embodiments discussed herein; and

[0053] Figure 13 is a flowchart showing an example method of manufacturing a fiber optic array unit having multiple layers according to some embodiments discussed herein. Detailed Description

[0054] Example embodiments of the present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the example embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Except Figures 11 to 13 for the reference numerals presented in, like reference numerals generally refer to like elements. For example, reference numerals 110, 610A, 610B, 710A, 710B, etc. each refer to an optical fiber. Additionally, unless specifically stated otherwise, any connection or attachment can be a direct or indirect connection or attachment.

[0055] Example embodiments provide a fiber optic array unit in which optical fibers are effectively positioned on the surface of a fiber optic array structure, where the surface is manufactured without grooves for each optical fiber. In Figures 1A to 1B , an example of such a fiber optic array unit 100 is shown, where Figure 1A a perspective view is provided, and where Figure 1B a front view is provided.

[0056] Figure 1A The covered optical fibers 106 are shown in. Each covered optical fiber 106 has an outer coating 108 and an optical fiber 110 within the outer coating 108. The optical fibers 110 form Figure 1A part of the fiber optic array unit 100 in. In some embodiments, the covered optical fibers 106 may be provided as part of an optical fiber ribbon, where multiple covered optical fibers 106 are held together. In the illustrated embodiment, the covered optical fibers 106 are stacked in two layers, and the outer coatings 108 of adjacent covered optical fibers 106 in each layer may be in contact with each other to minimize the pitch between the covered optical fibers 106. The pitch between the covered optical fibers 106 can be measured from the center of one covered optical fiber 106 to the center of an adjacent covered optical fiber 106. The covered optical fibers 106 have a larger cross-sectional area than the cross-sectional area of each optical fiber 110. Thus, when the outer coating 108 of the covered optical fiber 106 is removed, the pitch between the optical fibers 110 can be reduced compared to the pitch between the covered optical fibers 106, and the smaller-sized optical fibers 110 can be arranged in a single layer. Figure 3BAn example embodiment is shown where two layers of coated optical fibers 106 are provided, where the outer coating 108 is removed to expose the optical fiber 110 therein, and where the optical fibers 110 are combined into a single layer.

[0057] The fiber array unit 100 further includes a fiber array structure 102. The fiber array structure 102 has a surface 101 that defines a first groove 104A and a second groove 104B. In the illustrated embodiment, the surface 101 is the top surface of a raised portion of the fiber array structure 102. Additionally, the first groove 104A and the second groove 104B can have various shapes and sizes. In some embodiments, both the first groove 104A and the second groove 104B can be V-shaped grooves. However, the first groove 104A and the second groove 104B can have other shapes, such as a linear shape, a square shape, a rectangular shape, a trapezoidal shape, a circular shape, an oval shape, an asymmetric shape, or some other shape.

[0058] Additionally, the fiber array unit 100 includes a first guiding member 112A and a second guiding member 112B. As Figure 1A shown, the first guiding member 112A is partially received in the first groove 104A to assist in positioning the first guiding member 112A relative to the fiber array structure 102, and the second guiding member 112B is partially received in the second groove 104B to assist in positioning the second guiding member 112B relative to the fiber array structure 102. The first guiding member 112A and the second guiding member 112B can take various forms. In some embodiments, the guiding member can be a dowel pin or a dummy optical fiber. In some embodiments, the first guiding member 112A and the second guiding member 112B can be larger than the optical fiber 110 such that the cross-sectional area and / or height (which can be a diameter) of each of the guiding members 112A, 112B is greater than the cross-sectional area and / or height (which can be a diameter) of the individual optical fiber 110. The guiding members 112A, 112B and the optical fiber 110 can have a circular cross-section in some embodiments, but these components can have other cross-sectional shapes in other embodiments.

[0059] The surface 101 defines a first region 107 between the first groove 104A and the second groove 104B (see Figure 1C)。This first region 107 is configured to have no grooves, and in some embodiments, the first region 107 can act as a flat substrate. Each optical fiber in the optical fibers 110 is positioned between the first guiding member 112A and the second guiding member 112B. Thus, the optical fibers 110 are positioned adjacent to or in contact with the first region 107 of the surface 101, and the optical fibers 110 are effectively positioned relative to the optical fiber array unit 100 without the need for grooves for the optical fibers 110 in the optical fiber array unit 100. When the optical fibers 110 are disposed between the first guiding member 112A and the second guiding member 112B, the first guiding member 112A and the second guiding member 112B can effectively act as sidewalls to assist in positioning the optical fibers 110 in the correct horizontal position. The first guiding member 112A and the second guiding member 112B can restrict the horizontal movement of the optical fibers 110. The first guiding member 112A and the second guiding member 112B can achieve accurate passive optical alignment of the optical fibers 110. By providing an optical fiber array unit 100 that can effectively position the optical fibers 110 without grooves in the optical fiber array unit 100, the cost of manufacturing the optical fiber array unit 100 can be reduced.

[0060] In some embodiments, the first region 107 can define a flat plane such that the first region 107 can act as a flat substrate. However, in other embodiments, the first region 107 can have different shapes. For example, in other embodiments, the first region 107 of the surface 101 can be curved, wavy, or angled.

[0061] In some embodiments, the included optical fibers 110 and any dummy optical fibers 418A, 418B (see Figure 4B ) can be directly or indirectly fixed to the first region 107. This can be achieved in a variety of ways. For example, in Figure 1C , the optical fibers 110 are fixed to the first region 107 by an adhesive. The adhesive is applied in the gap 103 formed between adjacent optical fibers 110 and the first region 107. Figure 1D Another embodiment is shown in which the optical fibers 110 are fixed to the first region 107 by laser welding. Welding material 105 can be added by welding to assist in restricting the movement of the optical fibers 110 relative to the optical fiber array structure 102.

[0062] One or more fasteners can be utilized to assist in manufacturing the optical fiber array unit. Fasteners can be used to properly position the guiding members, optical fibers, and / or any dummy optical fibers. When the guiding members, optical fibers, and / or any dummy optical fibers are fixed to the optical fiber array structure, the fasteners can hold these components in place until fixation can be completed. Figures 2A to 2C Fasteners are shown for assisting in various stages of manufacturing the optical fiber array unit.

[0063] Figure 2AIs a perspective view showing a first exemplary fastener for forming an exemplary fiber optic array unit. As shown, the guide member is positioned in the groove of the fiber optic array structure 102. The first guide member 112A is positioned in the first groove 104A, and the second guide member 112B is positioned in the second groove 104B. As indicated by the downward arrow, a force (F) can be applied to the first fastener 214A, and the first fastener 214A can press the first guide member 112A and the second guide member 112B into place due to this downward force (F). This force (F) can also keep the first guide member 112A and the second guide member 112B in place. Figure 2A The first fastener 214A of is provided without any grooves, but grooves can be defined within the surface of the first fastener 214A to assist in positioning the guide member and / or other optical fibers (see, for example Figure 5B the fastener 514). In some embodiments, the first guide member 112A can be fixed in the first groove 104A, and the second guide member 112B can be fixed in the second groove 104B, and the fixing of the guide members 112A, 112B can occur with the first fastener 214A being used to assist in controlling the position of the guide members 112A, 112B. Once the guide members 112A, 112B are properly positioned and / or fixed, the first fastener 214A can be removed as Figure 2B shown.

[0064] Now referring to Figure 2C , a second fastener 214B is shown, where the second fastener 214B is used to assist in positioning the optical fiber 110. The second fastener 214B is sized such that the length between the edges of the first guide member 112A and the second guide member 112B is greater than or equal to the length (L) of the second fastener 214B. As indicated by the downward arrow, a force (F) is applied to the second fastener 214B, and the second fastener 214B pushes the optical fiber 110 into place due to this downward force (F). In this way, the second fastener 214B is pushed downward without interference from the first guide member 112A or the second guide member 112B. However, in some embodiments, the second fastener 214B can have a greater length. In some embodiments, the optical fiber 110 can be fixed relative to the fiber optic array structure 102, and the fixing of the optical fiber 110 can occur with the second fastener 214B being used to assist in controlling the position of the optical fiber 110. Once the optical fiber 110 is properly positioned and / or fixed, the second fastener 214B can be removed.

[0065] In Figure 2CIn the embodiment shown, the first guiding member 112A, the second guiding member 112B, and the optical fiber 110 extend to the front surface 202A of the optical fiber array structure 102, but do not extend beyond the front surface 202A. In other embodiments, the guiding members 112A, 112B, and / or the optical fiber 110 may extend beyond the front surface 202A. For example, in Figure 3A and 3B , the optical fiber 110 extends beyond the front surface 202A of the optical fiber array structure 102, but the guiding members 112A, 112B do not extend beyond the front surface 202A. In Figure 3C , the guiding members 112A, 112B extend beyond the front surface 202A of the optical fiber array structure 102, but the optical fiber 110 does not extend beyond the front surface 202A. In Figure 3D , the guiding members 112A, 112B and the optical fiber 110 extend beyond the front surface 202A of the optical fiber array unit 300C.

[0066] Figure 3C The optical fiber array unit 300B of

[0067] includes a guiding member that extends beyond the front surface 202A. This feature can be beneficial for assisting in aligning the optical fiber array unit 300B with an optical fiber ferrule or another optical coupling device to form an optical interconnect - the guiding member can be configured to be received within a slot or groove provided in the optical fiber ferrule or another optical coupling device, and this can assist in properly positioning the optical fiber 110.

[0067] By providing Figure 2C and Figures 3A to 3D the different methods shown, optical fiber array units can be selected that are configured to work with different mating mechanisms. In the case where the optical fiber 110 extends beyond the front surface 202A, the end face of the optical fiber 110 can be polished or laser cut to form an Ultra Physical Contact (UPC) fiber or an Angled Physical Contact (APC) fiber with a controlled surface roughness. Different roughness levels can be used at the end face of the optical fiber 110 - for example, the end face can have an optical surface, or the end face can have a rough surface. In the case where the first guiding member 112A and / or the second guiding member 112B extend beyond the front surface 202A, the end faces of these guiding members can undergo a similar end face treatment.

[0068] In some embodiments, dummy optical fibers can be utilized to position the optical fibers as needed. Dummy optical fibers can be used to adjust the pitch between optical fibers, and the dummy optical fibers can also be configured to fill the space left between the guiding member and the optical fiber. Figures 4A to 4B An example optical fiber array unit 400 showing the use of dummy optical fibers is shown, where Figure 4A a perspective view is provided, and where Figure 4B a front view is provided. Similar toFigure 1A The example fiber optic array unit 100 shown in Figures 4A to 4B The fiber optic array unit 400 of includes a fiber optic array structure 102 that defines a surface 101, where the surface 101 defines a first groove 104A and a second groove 104B. A first guiding member 112A is positioned in the first groove 104A, and a second guiding member 112B is positioned in the second groove 104B. A fiber 110 is also provided that is positioned between the first guiding member 112A and the second guiding member 112B.

[0069] In Figure 1A In , the fiber 110 extends in a single layer, where multiple fibers 110 extend from the first guiding member 112A all the way to the second guiding member 112B, and the first guiding member 112A and the second guiding member 112B contact the fiber 110 to assist in controlling the position of the fiber 110. In Figures 4A to 4B In , the fiber 110 also extends in a single layer, but the fiber 110 does not extend from the first guiding member 112A all the way to the second guiding member 112B, but rather there is a space between the fiber 110 and the first guiding member 112A, and there is also a space between the fiber 110 and the second guiding member 112B. These spaces may occur when using a different number of fibers 110. For example, when using sixteen fibers instead of thirty-two fibers and the length between the first groove 104A and the second groove 104B remains unchanged, the size of the space can be increased. Spaces may also occur when the length between the first groove 104A and the second groove 104B changes, when the size and / or shape of the fiber 110 changes, and / or for other reasons.

[0070] Dummy fibers may be provided to fill any gaps to assist in controlling the position of the fibers. Regardless of changes in the length between the grooves, the number of fibers used, or other variations, the dummy fibers can be provided in variable amounts to fill any gaps created between the fibers and the guiding members. Thus, the dummy fibers can be beneficial in adapting the fiber optic array unit to various usage scenarios.

[0071] In Figure 4A In , a first set of dummy fibers 418A and a second set of dummy fibers 418B are provided. The first set of dummy fibers 418A may include only one dummy fiber, but the first set of dummy fibers 418A may also include multiple dummy fibers. Similarly, the second set of dummy fibers 418B may include only one dummy fiber, but the second set of dummy fibers 418B may include multiple dummy fibers. The first set of dummy fibers 418A and the second set of dummy fibers 418B contact a first region 107.

[0072] The first set of dummy optical fibers 418A can fill the space left between the first guiding member 112A and the optical fiber 110. The dummy optical fibers in the first set of dummy optical fibers 418A can contact the first guiding member 112A, and the same or another dummy optical fiber in the first set of dummy optical fibers 418A can contact the optical fiber in the optical fiber 110, where the optical fiber is located at the first end of the optical fiber 110. Similarly, the second set of dummy optical fibers 418B can fill the space left between the second guiding member 112B and the optical fiber 110. The dummy optical fibers in the second set of dummy optical fibers 418B can contact the second guiding member 112B, and the same or another dummy optical fiber in the second set of dummy optical fibers 418B can contact the optical fiber in the optical fiber 110, where the optical fiber is located at the second end of the optical fiber 110.

[0073] In Figures 4A to 4B the illustrated embodiment of, the first guiding member 112A, the second guiding member 112B, the dummy optical fibers in the first set of dummy optical fibers 418A, and the dummy optical fibers in the second set of dummy optical fibers 418B each have a circular cross-section. However, in other embodiments, some or all of these components may have other cross-sections. For example, some or all of these components may have a square, rectangular, trapezoidal, elliptical, asymmetric, or some other shaped cross-sectional shape. Additionally, in Figures 4A to 4B the illustrated embodiment of, the first guiding member 112A and the second guiding member 112B have a first cross-sectional area, and the optical fiber 110, the dummy optical fibers in the first set of dummy optical fibers 418A, and the dummy optical fibers in the second set of dummy optical fibers 418B have a second cross-sectional area. In some such exemplary embodiments, the first cross-sectional area is greater than the second cross-sectional area. By providing guiding members with a larger cross-sectional area and / or a larger height, the guiding members can effectively act as sidewalls to assist in positioning the optical fiber 110 and any dummy optical fibers. However, in other embodiments, the relative sizes of the optical fiber 110, the dummy optical fibers, and the guiding members may be equal, or the guiding members may actually have a smaller cross-sectional area than the optical fiber 110 and / or the dummy optical fibers.

[0074] Other exemplary optical fiber array units may be provided where there is a space left between the guiding member and the optical fiber, and the optical fiber can be effectively positioned without using dummy optical fibers. Figure 5A A perspective view showing such an exemplary optical fiber array unit 500 is presented. The first guiding member 112A, the second guiding member 112B, and the optical fiber 110 are provided. There is a gap left between the optical fiber 110 and the first guiding member 112A, and there is also a gap left between the optical fiber 110 and the second guiding member 112B. The optical fiber 110 is fixed in place relative to the optical fiber array structure 102 (e.g., using an adhesive or by laser welding).

[0075] Figure 5B 、 5C and 5D show for assisting in formingFigure 5A The fastener 514 of the fiber optic array unit 500. Different from Figure 2A the fastener 214A and Figure 2C the fastener 214B, Figures 5B to 5C the fastener 514 includes grooves 520 configured to assist in positioning the optical fibers 110. Each of the grooves 520 is configured to partially receive an optical fiber 110. Additionally, different from Figure 2A the fastener 214A and Figure 2C the fastener 214B, Figures 5B to 5C the fastener 514 includes a first groove 522A and a second groove 522B, the first groove 522A and the second groove 522B being configured to assist in positioning the fastener 514 relative to the first guiding member 112A and the second guiding member 112B. The first groove 522A is configured to partially receive the first guiding member 112A, and the second groove 522B is configured to partially receive the second guiding member 112B. The grooves 520 are provided between the first groove 522A and the second groove 522B. In the illustrated embodiment, the grooves 520, the first groove 522A, and the second groove 522B are V-shaped grooves. However, the grooves 520, 522A, 522B can have other shapes, such as a linear shape, a square shape, a circular shape, an oval shape, an asymmetric shape, or some other shape.

[0076] As indicated by the downward arrow, a force (F) can be applied to the fastener 514, and the fastener 514 can, due to this force (F), push the first guiding member 112A, the second guiding member 112B, and the optical fibers 110 into proper positions. In some embodiments, the fastener 514 can be used to retain the first guiding member 112A, the second guiding member 112B, and the optical fibers 110 in proper positions until these components are fixed to the fiber optic array structure 102.

[0077] Although the grooves 520, the first groove 522A, and the second groove 522B are provided in Figures 5B to 5C the fastener 514, alternative embodiments of the fastener can include only the grooves 520 without the first groove 522A or the second groove 522B. Additionally, other alternative embodiments of the fastener can include only the first groove 522A and / or the second groove 522B and may not have the grooves 520.

[0078] In some embodiments, the fastener 514 can be removed after the first set of optical fibers 110 are positioned and / or fixed, thereby creating Figure 5AThe optical fiber array unit 500 shown in [the figure]. However, in other embodiments, the fastener 514 may remain on the optical fiber array structure 102. In the case where the fastener 514 is retained, after the first group of optical fibers 110 are positioned and / or fixed, the fastener 514 may be fixed relative to the optical fiber array structure 102, and the fastener 514 may act as a cover plate for the optical fibers and the guiding members. The fixing of the fastener 514 can be performed by various methods. For example, the fastener 514 can be fixed by laser welding or by using an adhesive.

[0079] An optical fiber array unit may be provided with a spacing between different groups of optical fibers. Figures 6A to 6C An example of such an optical fiber array unit 600 is shown, where Figure 6A is a perspective view showing the optical fiber array unit 600, where Figure 6B is a perspective view showing an example fastener 614 for assisting in forming the optical fiber array unit 600, and where Figure 6C is a front view showing the fastener 614 for assisting in forming the optical fiber array unit 600.

[0080] First referring to Figure 6A , the optical fiber array unit 600 is provided with a first group of optical fibers 610A and a second group of optical fibers 610B. The first group of optical fibers 610A may extend from a first group of covered optical fibers 606A, and the second group of optical fibers 610B may extend from a second group of covered optical fibers 606B. A space may be retained between the first group of optical fibers 610A and the second group of optical fibers 610B.

[0081] Figure 6A This spacing and positioning of the optical fibers shown in [the figure] can be achieved using Figures 6B to 6C the fastener 614 shown in [the figure]. As Figure 6C shown in [the figure], the fastener 614 includes a first groove 522A and a second groove 522B. The first groove 522A is configured to partially receive the first guiding member 112A to assist in positioning the fastener 614, and the second groove 522B is configured to partially receive the second guiding member 112B to assist in positioning the fastener 614. The fastener 614 further includes a first group of grooves 620A and a second group of grooves 620B. The first group of grooves 620A is configured to partially receive the first group of optical fibers 610A to assist in positioning and / or fixing the first group of optical fibers 610A, and the second group of grooves 620B is configured to partially receive the second group of optical fibers 610B to assist in positioning and / or fixing the second group of optical fibers 610B. Although in the Figure 6C embodiment shown in [the figure], various grooves are provided at specific positions, in other embodiments, the grooves may be provided at other positions such that the optical fibers can be positioned differently. The first group of grooves 620A and the second group of grooves 620B can assist in controlling the pitch between the optical fibers and the distance between the optical fibers and the guiding members.

[0082] In other embodiments, the spacing and positioning of the optical fibers as shown in Figure 6A may be achieved by using dummy optical fibers, where the dummy optical fibers are disposed in the spaces between the first guiding member 112A and the first set of optical fibers 610A, between the first set of optical fibers 610A and the second set of optical fibers 610B, and / or between the second set of optical fibers 610B and the second guiding member 112B. In some embodiments, once the optical fibers are positioned and / or fixed, the dummy optical fibers may be removed from the fiber array unit, but in other embodiments, the dummy optical fibers may be retained as part of the fiber array unit.

[0083] As Figures 6B to 6C indicated by the downward arrow in, a force (F) may be applied to the fastener 614, and the fastener 614 may push the first guiding member 112A, the second guiding member 112B, and the optical fibers into place due to this downward force (F). In some embodiments, the fastener 614 may be used to retain the first guiding member 112A, the second guiding member 112B, and the optical fibers in place until these components are fixed to the fiber array structure 102.

[0084] In some embodiments, the optical fibers may be stacked in multiple layers in the fiber array unit. Figures 7A to 7B An exemplary fiber array unit 700 is shown, where Figure 7A a perspective view is provided, and where Figure 7B a front view is provided. In the fiber array unit 700, the first layer may be formed by the first set of optical fibers 710A and dummy optical fibers. The first set of optical fibers 710A is disposed between the first guiding member 112A and the second guiding member 112B. The first set of dummy optical fibers 418A is disposed in the first layer between the first set of optical fibers 710A and the first guiding member 112A, and the second set of dummy optical fibers 418B is disposed in the first layer between the first set of optical fibers 710A and the second guiding member 112B. However, in other embodiments, the first layer may be arranged without any dummy optical fibers. Thirty-two optical fibers are provided in the first set of optical fibers 710A, and four dummy optical fibers are provided in each of the first set of dummy optical fibers 418A and the second set of dummy optical fibers 418B, but in other embodiments, the number of optical fibers and dummy optical fibers may vary. The first guiding member 112A and the second guiding member 112B may act as sidewalls, where these guiding members each contact the dummy optical fibers to provide a constraint on the horizontal movement of the dummy optical fibers and the first set of optical fibers 710A.

[0085] The second layer may be disposed above the first layer. In Figures 7A to 7BIn an example fiber optic array unit 700, the second layer contains only the second set of optical fibers 710B. Thirty-two optical fibers are provided in the second set of optical fibers 710B, but in other embodiments, the number of optical fibers can vary. In some embodiments, the second layer may also contain dummy optical fibers. The second layer can be arranged such that the first set of optical fibers 710A is positioned vertically between the second set of optical fibers 710B and the first region 107 of the fiber optic array structure 102. Additionally, optical fibers can be arranged in each layer such that they contact one or more optical fibers in another layer, and each optical fiber in the second set of optical fibers 710B can contact another optical fiber in the first set of optical fibers 710A.

[0086] The optical fibers in each layer can be stacked in a staggered manner. For example, the optical fibers in the second set of optical fibers 710B sink into the gaps formed between adjacent optical fibers in the first layer. Thus, the optical fibers in the second set of optical fibers 710B can sink until they contact two optical fibers from the first optical fiber layer. Most of the optical fibers in the second set of optical fibers 710B contact two optical fibers in the first set of optical fibers 710A. However, in the illustrated embodiment, the leftmost optical fiber in the second set of optical fibers 710B contacts only one optical fiber in the first set of optical fibers 710A because the leftmost optical fiber also contacts a dummy optical fiber. By stacking the optical fibers in a staggered manner, the optical fiber density in the fiber optic array unit 700 can be increased.

[0087] Additionally, fasteners can be utilized to assist in positioning the fiber optic layers to form Figure 7A the fiber optic array unit 700. Figure 7C Provided is a front view showing a first example fastener 714A for assisting in forming Figure 7A the fiber optic array unit 700. The first set of optical fibers 710A can be placed between a first guiding member 112A and a second guiding member 112B, and the first set of dummy optical fibers 418A and the second set of dummy optical fibers 418B can also be placed in the desired positions between the guiding members to assist in controlling the position of the first set of optical fibers 710A. In the case of placing the optical fibers and the dummy optical fibers, the first fastener 714A can be utilized to assist in positioning the optical fibers. A downward force (F) can be applied to the first fastener 714A to generate a downward force on the underlying optical fibers. As shown, the first fastener 714A is arranged such that there are no grooves on the bottom surface of the first fastener 714A, but in other embodiments, grooves can be provided at this bottom surface as another measure for assisting in positioning the optical fibers. With the first fastener 714A in place, the first set of optical fibers 710A and / or any dummy optical fibers can be fixed to the fiber optic array structure 102. Once these optical fibers have been fixed, the first fastener 714A can be removed to allow the addition of additional fiber optic layers.

[0088] Figure 7D is a view showing for assisting in forming Figure 7AFront view of the second instance fastener 714B of the fiber optic array unit. This second fastener 714B is utilized to effectively position the second fiber optic layer. In the illustrated embodiment, this second fiber optic layer includes a second group of optical fibers 710B. The second fastener 714B includes a plurality of grooves 720 on the bottom surface of the second fastener 714B. An appropriate number of grooves may be provided to permit each of the optical fibers in the second layer to have a corresponding groove. In Figure 7D the illustrated embodiment, thirty-two optical fibers are provided in the second layer, and thus thirty-two grooves 720 are provided in the second fastener 714B. Although grooves 720 are provided in the second fastener 714B in the illustrated embodiment, in other embodiments other fasteners without grooves may be utilized to assist in positioning the second layer. In some embodiments, the first fastener 714A may actually be used to position multiple fiber optic layers, rather than using a second fastener 714B different from the first fastener 714A to position the second layer.

[0089] Other fiber optic array units with optical fibers in multiple layers may be provided. Figures 8A to 8B An example of an alternative fiber optic array unit 800 is shown, wherein Figure 8A a front view is provided, and wherein Figure 8B a perspective view is provided. In the fiber optic array unit 800, the first fiber optic layer is arranged without any dummy optical fibers. The first fiber optic layer consists only of a first group of optical fibers 810A, wherein thirty-three optical fibers are provided in this first layer. The second fiber optic layer also consists only of a second group of optical fibers 810B, wherein thirty-two optical fibers are provided in this second layer. The first group of optical fibers 810A of the first layer are vertically positioned between the first region 107 and the second group of optical fibers 810B.

[0090] The layers may be stacked in an interleaved manner. The optical fibers of the second layer may sink into the gaps between adjacent optical fibers in the first layer such that each optical fiber of the second layer contacts two optical fibers of the first layer. By stacking the optical fibers in this manner, the density of the optical fibers in the fiber optic array unit 800 can be increased.

[0091] Figure 8C is a diagram showing for assisting in forming Figure 8AFront view of the first example fastener 814A of the fiber optic array unit 800. The first fastener 814A can be utilized to assist in positioning the first set of optical fibers 810A that form the first layer. The first fastener 814A includes a plurality of grooves 820A in the bottom surface of the first fastener 814A. The number of grooves 820A provided can correspond to the number of optical fibers disposed in the first set of optical fibers 810A. In the illustrated embodiment, thirty-three optical fibers are disposed in the first set of optical fibers 810A, and thirty-three grooves 820A are provided in the first fastener 814A. The grooves 820A can help control the position of the optical fibers and can control the pitch between adjacent optical fibers. The first fastener 814A can be utilized to assist in positioning the optical fibers in the first set of optical fibers 810A, and the first fastener 814A can remain in place until these optical fibers are fixed relative to the fiber optic array structure 102. Once these optical fibers are fixed, the first fastener 814A can be removed so that additional fiber optic layers can be added.

[0092] Now referring to Figure 8D , there is provided a front view showing a second example fastener 814B for assisting in forming Figure 8A the fiber optic array unit 800. The second fastener 814B can be utilized to assist in positioning the second set of optical fibers 810B that form the second layer. The second fastener 814B includes a plurality of grooves 820B on the bottom surface of the second fastener 814B. The number of grooves 820B provided can correspond to the number of optical fibers disposed in the second set of optical fibers 810B. In the illustrated embodiment, thirty-two optical fibers are disposed in the second set of optical fibers 810B, and thirty-two grooves 820B are provided in the second fastener 814B. The second fastener 814B can be utilized to assist in positioning the optical fibers in the second set of optical fibers 810B, and the second fastener 814B can remain in place until these optical fibers are fixed relative to the fiber optic array structure 102. The second set of optical fibers 810B can be fixed relative to the fiber optic array structure 102 by directly fixing the second set of optical fibers 810B to the first set of optical fibers 810A, which may have been directly fixed to the fiber optic array structure 102. Once the second set of optical fibers 810B is fixed relative to the fiber optic array structure 102, the second fastener 814B can be removed so that additional fiber optic layers (if any) can be added. Alternatively, the second fastener 814B can be retained and / or fixed to the fiber optic array structure 102.

[0093] Three or more guiding members can be provided in some fiber optic array units to further assist in controlling the position of the optical fibers. Figure 9A is a perspective view showing an example fiber optic array unit 900 using three guiding members. Additionally, Figure 9B and 9C show for assisting in forming Figure 9AAn example fastener 914 of the fiber optic array unit 900, wherein Figure 9B A perspective view is provided, and Figure 9C A front view is provided. As Figures 9A to 9C shown, the fiber optic array structure 102 may include a first groove 104A, a second groove 104B, and a third groove 104C. Additionally, as Figure 9C shown, the fastener 914 may include a first groove 522A, a second groove 522B, and a third groove 522C. The fiber optic array unit 900 may further include a first guiding member 112A, a second guiding member 112B, and a third guiding member 112C.

[0094] Each of the guiding members is partially received in a corresponding groove of the fiber optic array structure 102 and another corresponding groove of the fastener 914. The first guiding member 112A is partially received in the first groove 104A of the fiber optic array structure 102, and the first guiding member 112A is also partially received in the first groove 522A of the fastener 914. The second guiding member 112B is partially received in the second groove 104B of the fiber optic array structure 102, and the second guiding member 112B is also partially received in the second groove 522B of the fastener 914. The third guiding member 112C is partially received in the third groove 104C of the fiber optic array structure 102, and the third guiding member 112C is also partially received in the third groove 522C of the fastener 914.

[0095] Including additional guiding members may be beneficial for further controlling the position of the optical fibers 110 in the fiber optic array unit 900. Including three or more guiding members may also be beneficial for limiting the amount of force applied to each individual optical fiber 110 when any downward force (F) is applied to the fastener 914.

[0096] In some embodiments, the optical fibers disposed in the fiber optic array unit may be formed of two or more different optical fibers spliced together. Figure 10An example of such a fiber optic array unit 1024 is shown having optical fibers 1026 disposed on a membrane 1050 positioned on a surface 1042 of a fiber optic array structure 1040. The optical fibers 1026 can be laser welded to the surface 1042 of the fiber optic array structure 1040 by directing heat to the membrane 1050. In some embodiments, other bonding methods can be used to weld the optical fibers 1026 to the surface 1042 of the substrate. Notably, the optical fibers 1026 can be laser welded to the fiber optic array structure using the methods disclosed in the following patents: U.S. Patent No. 10,345,533, filed on February 15, 2018, titled "Assemblies, Optical Connectors and Methods of Bonding Optical Fibers to Substrates"; U.S. Patent No. 10,422,961, filed on February 10, 2018, titled "Fiber Array Formed Using Laser Bonded Optical Fibers"; U.S. Patent No. 10,545,293, filed on May 13, 2019, titled "Assemblies, Optical Connectors and Methods of Bonding Optical Fibers to Substrates"; and U.S. Patent No. 10,746,937, filed on October 25, 2019, titled "Assemblies, Optical Connectors and Methods of Bonding Optical Elements to Substrates", which are assigned to the assignee and applicant of the present application and each of which is incorporated herein by reference in its entirety.

[0097] The optical fiber 1026 can define a length L extending between a first end 1026A and a second end 1026B, where the second end 1026B is a cut end. An optical path 1056 can extend along the length L of the optical fiber 1026. The optical path 1056 can be configured such that the length L of the optical fiber 1026 defines the output characteristics of an optical signal extending from the second end 1026B of the optical fiber 1026 and thereby defines the optical path 1056. The optical path 1056 can extend through the core 1036 of the optical fiber 1026, and a cladding can surround the core 1036 of the optical fiber 1026. The cladding can contribute to the refractive characteristics of the optical fiber 1026.

[0098] In some embodiments, the length L of at least one optical fiber 1026 can determine the output characteristics of the optical fiber 1026. In this regard, a portion of the optical fiber 1026 can define an optical variation portion, where the output characteristics of the output signal vary according to the position along the optical variation portion. By positioning the second end 1026B at different positions along the optical variation portion, different output characteristics can be obtained (e.g., selecting the position to locate the second end 1026B to achieve customized output characteristics). The output characteristics can be, for example, the focusing, collimation, and / or divergence characteristics of the light rays and / or light beams propagating within the optical fiber 1026.

[0099] The second end 1026B can be disposed at various positions relative to the end face 1048 of the optical fiber array structure 1040. In Figure 10 , the second end 1026B of the optical fiber 1026 is aligned with the end face 1048 of the optical fiber array structure 1040. In some embodiments, the second end 1026B of the optical fiber 1026 can be recessed from the end face 1048 of the optical fiber array structure 1040, or the second end 1026B can extend beyond the end face 1048.

[0100] The second end 1026B can be inserted into an optical fiber ferrule, a V-groove, or other optical coupling devices to transmit and transfer data and optical information between the optical fiber 1026 and another device. In some embodiments, the second end 1026B of the optical fiber 1026 can be recessed from the end face of the optical fiber ferrule, the V-groove, or other optical coupling devices to transmit and transfer data and optical information between the optical fiber 1026 and another device.

[0101] In some embodiments, as shown in Figure 10 , the optical fiber 1026 can be formed by splicing a first optical fiber 1030 and a second optical fiber 1032 together at a splicing position 1034. The core of the first optical fiber 1030 can be surrounded by a cladding 1052, which can contribute to the refractive characteristics of the first optical fiber 1030, and the core of the second optical fiber 1032 can be surrounded by a cladding 1054, which can contribute to the refractive characteristics of the second optical fiber 1032. In some embodiments, the optical fiber length of the second optical fiber 1032 extending between the splicing position 1034 and the second end 1026B can define the output characteristics of the optical fiber 1026.

[0102] In some embodiments, a film 1050 is disposed under a portion 1028 of the first optical fiber 1030, and the second end 1026B is located on the second optical fiber 1032. In some embodiments, the portion 1028 of the optical fiber can extend across the surface 1042 of the optical fiber array structure 1040, while in other embodiments, the portion 1028 can partially extend across the surface 1042 of the optical fiber array structure 1040.

[0103] In some embodiments, the optical fiber 1026 is located in eight optical fiber ribbons positioned on the surface 1042 of the optical fiber array structure 1040, where the optical fiber 1026 extends from a first side 1046 of the optical fiber array structure 1040 to a second side 1044 of the optical fiber array structure 1040. In some embodiments, the optical fibers 1026 in the optical fiber ribbons can extend from the first side 1046 to the second side 1044 of the optical fiber array structure 1040, while in other embodiments, the optical fibers 1026 within the optical fiber ribbons can extend partially between the first side 1046 and the second side 1044.

[0104] In some embodiments, the optical fibers 1026 can be ribbon-shaped (e.g., adhered to each other), in a flat configuration or in a rollable configuration where the optical fibers 1026 are intermittently joined.

[0105] In some embodiments, the first optical fiber 1030 can be a single-mode optical fiber. A single-mode optical fiber supports only one linearly polarized (LP01) mode per polarization direction at the system wavelength. In some embodiments, the first optical fiber 1030 can have low bend loss, for example less than 1 dB when wound around a 25-mm diameter mandrel, less than 1 dB when wound around a 20-mm diameter mandrel, and more preferably less than 1 dB when wound around a 15-mm diameter mandrel. In some embodiments, the first optical fiber 1030 can include a step-index core. In some embodiments, the first optical fiber 1030 can include a circular step-index core. In some embodiments, the first optical fiber 1030 can include a core having an alpha value greater than 10. In some embodiments, the first optical fiber 1030 can include a graded-index core. In some embodiments, the first optical fiber 1030 can include a core having an alpha value less than 10. In some embodiments, the first optical fiber 1030 can include a 22-meter cut-off wavelength less than 1260 nm, less than 1230 nm, or more preferably less than 1200 nm. In some embodiments, the first optical fiber 1030 can include a 2-meter cut-off wavelength less than 1260 nm, less than 1230 nm, or more preferably less than 1200 nm.

[0106] In some embodiments, the second optical fiber 1032 is a multimode fiber (MMF), where the MMF can support more than one linear polarization mode at the system wavelength. More precisely, in some embodiments, the second optical fiber 1032 is configured as an MMF gradient index (GRIN) lens, which allows multiple light rays to propagate within the core 1036. In some embodiments, the second optical fiber 1032 may have a parabolic gradient index profile (e.g., the curvature of the core α = 2), but in other embodiments, the curvature of the core of the MMF GRIN lens may not be parabolic (e.g., the curvature of the core α is not equal to 2). In some embodiments, the second optical fiber 1032 may have a core 1036. The core 1036 may have a diameter of 25 microns, 50 microns, 62.5 microns, or 100 microns. In some embodiments, the gradient index profile may define a core curvature value of 1.80 > α > 2.20.

[0107] Also contemplated is a method of fabricating a fiber array unit, and Figure 11 is a flow chart showing an exemplary method 1100 of fabricating a fiber array unit. At operation 1102, a first set of optical fibers, a first guiding member, and a second guiding member are provided. Additionally, at operation 1102, a fiber array structure is provided. The fiber array structure has a surface. This surface defines a first groove and a second groove, and the surface defines a first region between the first groove and the second groove. This first region is provided without any grooves. A dummy optical fiber may also be provided at operation 1102.

[0108] At operation 1104, the guiding members are positioned in the grooves of the fiber array structure. The first guiding member is positioned in the first groove, and the second guiding member is positioned in the second groove. At operation 1106, the first guiding member and the second guiding member may be pressed into their respective grooves using fasteners. By doing so, the positioning of the first guiding member and the second guiding member can be further improved.

[0109] At operation 1108, the guiding members are fixed in the grooves, where the first guiding member is fixed at the first groove and where the second guiding member is fixed at the second groove. Laser welding or an adhesive may be used to fix the guiding members, but other methods for fixing the guiding members may also be utilized. When performing operation 1108, the fasteners utilized at operation 1106 may continue to be used to press the guiding members into the grooves, and the fasteners are removed at operation 1110.

[0110] At operation 1112, the first set of optical fibers is positioned such that each optical fiber in the first set of optical fibers contacts the first region so as to be positioned between the first guiding member and the second guiding member. In the case where a dummy optical fiber is utilized, at operation 1114, the dummy optical fiber may be positioned between the first guiding member and the second guiding member.

[0111] At operation 1116, the first set of optical fibers and any dummy optical fibers are pressed into place using a fastener. In some embodiments, the fastener utilized at operation 1116 can be the same fastener as the fastener utilized at operation 1106, but in other embodiments, different fasteners can be utilized at these operations.

[0112] At operation 1118, the first set of optical fibers is fixed relative to the fiber array structure. In the case where dummy optical fibers are utilized, at operation 1118, these dummy optical fibers can also be fixed relative to the fiber array structure. The first set of optical fibers and any dummy optical fibers can be fixed in various ways. In some example embodiments, laser welding or an adhesive can be utilized to fix the first set of optical fibers and any dummy optical fibers.

[0113] When performing operation 1118, the fastener utilized at operation 1116 can continue to be used to press the first set of optical fibers and any dummy optical fibers into the grooves, and the fastener is removed at operation 1120. At operation 1120, the fastener utilized at operation 1116 can be removed. Additionally, at operation 1122, a cover plate can be added (although in some embodiments, the cover plate can be optional). However, in some embodiments, the fastener utilized at operation 1116 can be left in place, and the fastener can act as the cover plate.

[0114] Figure 12 is a flowchart showing another example method 1200 of manufacturing a fiber array unit. In Figure 12 method 1200, a guiding member, an optical fiber, and any dummy optical fibers are simultaneously pressed into place using a fastener.

[0115] At operation 1202, a first set of optical fibers, a first guiding member, and a second guiding member are provided. Additionally, at operation 1202, a fiber array structure is provided. The fiber array structure has a surface. This surface defines a first groove and a second groove, and the surface defines a first region between the first groove and the second groove. This first region is provided without any grooves. Dummy optical fibers can also be provided at operation 1202.

[0116] At operation 1204, the guiding members are positioned in the grooves of the fiber array structure. The first guiding member is positioned in the first groove, and the second guiding member is positioned in the second groove.

[0117] At operation 1206, the first set of optical fibers can be positioned such that each optical fiber in the first set of optical fibers contacts the first region to be positioned between the first guiding member and the second guiding member.

[0118] At operation 1208, dummy optical fibers can be provided and positioned between the first guiding member and the second guiding member. The dummy optical fibers can assist in controlling the position of the optical fibers as discussed herein.

[0119] At operation 1210, the first guiding member, the second guiding member, the first set of optical fibers, and the dummy optical fiber may be pressed into place using fasteners.

[0120] At operation 1212, the first guiding member, the second guiding member, the first set of optical fibers, and the dummy optical fiber may be fixed in place. The guiding members may be fixed in grooves, where the first guiding member is fixed at a first groove and where the second guiding member is fixed at a second groove. Laser welding or adhesives may be used to fix the guiding members, optical fibers, and dummy optical fiber, but other methods for fixing the guiding members may also be utilized.

[0121] At operation 1214, the fasteners may be removed. At operation 1216, a cover plate may be added (although in some embodiments, the cover plate may be optional). However, in some embodiments, the fasteners may not be removed at operation 1214 and the fasteners may effectively act as the cover plate. In such embodiments, at operation 1212, the fasteners may be fixed in place relative to the optical fiber array structure.

[0122] In some embodiments, one or more additional optical fiber layers may be added to the optical fiber array unit produced by Figure 11 method 1100 or Figure 12 method 1200. Method 1100 or Figure 11 method 1200 may be utilized to provide an optical fiber array unit having a single optical fiber layer. Figure 12 Method 1300 of Figure 13 may be performed after performing Figure 11 method 1100 or Figure 12 method 1200, and method 1300 may be utilized to add one or more additional optical fiber layers to the optical fiber array unit. As shown, method 1300 may be repeatedly performed to provide additional optical fiber layers until the desired number of layers has been included.

[0123] ​​​At operation 1302, an additional optical fiber is positioned on top of the previously positioned optical fibers. The additional optical fiber can be a second group of optical fibers, but the additional optical fiber can be a third group of optical fibers or another group of optical fibers. Additionally, at operation 1304, an additional dummy optical fiber can be positioned on top of the previously positioned optical fibers. The previously positioned optical fibers include a first group of optical fibers, and the previously positioned optical fibers can also include dummy optical fibers. In some embodiments, the additional optical fiber can be positioned such that the previously positioned optical fibers are vertically positioned between the first region and the additional optical fiber. In some embodiments, the additional optical fiber and the additional dummy optical fiber can be positioned at operations 1302 and 1304 such that these optical fibers rest in the gaps between two adjacent optical fibers on top of the previously positioned optical fibers. In some embodiments, the additional optical fiber and the additional dummy optical fiber can be naturally positioned to rest in these gaps due to gravity, and thus, the positioning at operations 1302 and 1304 can act as a form of passive alignment.

[0124] At operation 1306, fasteners can be used to press the additional optical fiber and any additional dummy optical fiber into place. At operation 1308, the additional optical fiber and the additional dummy optical fiber can be fixed in place. The fixing can occur in various ways. For example, the additional optical fiber and the additional dummy optical fiber can be fixed by using an adhesive or by laser welding. When performing operation 1308, the fasteners utilized at operation 1306 can continue to be used to press the optical fibers into place, and the fasteners are removed at operation 1310.

[0125] At operation 1312, a determination can be made as to whether an additional layer of optical fibers should be added. If the answer is yes, method 1300 can return to operation 1302, and operations 1302 through 1310 can be repeatedly performed until the desired number of layers have been added. Alternatively, if the answer at the determination of operation 1312 is no, method 1300 can proceed to operation 1314.

[0126] At operation 1314, a cover plate can be added (although in some embodiments, the cover plate can be optional). In some embodiments, the fasteners utilized at operation 1306 can act as the cover plate. In this case, operation 1310 is not performed, and the fasteners are retained on the optical fiber array unit. Additionally, at operation 1308, the fasteners can be fixed in place relative to the optical fiber array structure, where the fasteners are used as the cover plate.

[0127] Conclusion

[0128] Benefiting from the teachings presented in the foregoing description and the associated drawings, those skilled in the art to which this invention pertains will envision many modifications and other embodiments of the invention set forth herein. Accordingly, it is to be understood that the embodiments of the invention are not limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the invention. Moreover, although the foregoing description and the associated drawings describe example embodiments in the context of certain example combinations of elements and / or functions, it should be appreciated that alternative embodiments may provide different combinations of elements and / or functions without departing from the scope of the invention. In this regard, for example, combinations of different elements and / or functions than those explicitly described above are also encompassed within the scope of the invention. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. An optical fiber array unit, the optical fiber array unit comprising: A first group of optical fibers; A first guiding member and a second guiding member; And An optical fiber array structure having a surface that defines a first groove and a second groove, the surface defining a first region between the first groove and the second groove, Wherein the first region is arranged without any grooves, Wherein the first guiding member is at least partially received in the first groove to assist in positioning the first guiding member relative to the optical fiber array structure, wherein the second guiding member is at least partially received in the second groove to assist in positioning the second guiding member relative to the optical fiber array structure, and wherein each optical fiber in the first group of optical fibers is positioned between the first guiding member and the second guiding member.

2. The optical fiber array unit according to claim 1, the optical fiber array unit further comprising: A second group of optical fibers, Wherein the first group of optical fibers is vertically positioned between the first region and the second group of optical fibers, and Wherein each optical fiber in the second group of optical fibers contacts another optical fiber in the first group of optical fibers.

3. The optical fiber array unit according to claim 2, wherein the optical fibers in the second group of optical fibers are positioned such that the optical fibers contact two optical fibers in the first group of optical fibers.

4. The optical fiber array unit according to claim 3, wherein the first group of optical fibers and the second group of optical fibers are stacked in an interleaved manner.

5. The optical fiber array unit according to claim 1, wherein the first group of optical fibers is fixed to the first region.

6. The optical fiber array unit according to claim 5, wherein the first group of optical fibers is fixed to the first region by laser welding or by an adhesive.

7. The optical fiber array unit according to claim 1, the optical fiber array unit further comprising: A first group of one or more dummy optical fibers; And A second group of one or more dummy optical fibers, Wherein the first group of one or more dummy optical fibers and the second group of one or more dummy optical fibers contact the first region, wherein a first dummy optical fiber in the first group of one or more dummy optical fibers contacts the first guiding member, wherein the first dummy optical fiber or a second dummy optical fiber in the first group of one or more dummy optical fibers contacts a first optical fiber in the first group of optical fibers, wherein a first dummy optical fiber in the second group of one or more dummy optical fibers contacts the second guiding member, wherein the first dummy optical fiber or a second dummy optical fiber in the second group of one or more dummy optical fibers contacts a second optical fiber in the first group of optical fibers, wherein the first optical fiber in the first group of optical fibers is positioned at a first end of the first group of optical fibers, wherein the second optical fiber in the first group of optical fibers is positioned at a second end of the first group of optical fibers, and wherein the second end of the first group of optical fibers is opposite to the first end of the first group of optical fibers.

8. The optical fiber array unit according to any one of claims 1, 2 or 7, wherein the first groove and the second groove are both V-shaped grooves.

9. The optical fiber array unit according to any one of claims 1, 2 or 7, wherein the first region defines a flat plane.

10. The optical fiber array unit according to any one of claims 1, 2 or 7, wherein the first guiding member and the second guiding member are at least one of a dowel pin, an optical fiber or a dummy optical fiber.

11. The optical fiber array unit according to any one of claims 1, 2 or 7, wherein the first guiding member defines a cross-sectional area of the first guiding member, wherein the optical fibers in the first group of optical fibers define a cross-sectional area of the optical fiber, and wherein the cross-sectional area of the first guiding member is greater than the cross-sectional area of the optical fiber.

12. The optical fiber array unit according to any one of claims 1, 2 or 7, wherein the first group of optical fibers is positioned by applying a force to the first group of optical fibers through a first fastener.

13. The optical fiber array unit according to claim 12, wherein the first fastener defines a first groove and a second groove, wherein the first groove is configured to at least partially receive the first guiding member, and the second groove is configured to at least partially receive the second guiding member.

14. The optical fiber array unit according to claim 13, wherein the first fastener defines a plurality of grooves positioned between the first groove and the second groove, and wherein each of the plurality of grooves is configured to at least partially receive an optical fiber in the first group of optical fibers.

15. The optical fiber array unit according to claim 12, wherein the first fastener defines a plurality of grooves, and wherein each of the plurality of grooves is configured to at least partially receive an optical fiber in the first group of optical fibers.

16. The optical fiber array unit according to claim 12, wherein the first fastener is removed after positioning the first group of optical fibers.

17. The optical fiber array unit according to claim 16, the optical fiber array unit further comprising: a second group of optical fibers, wherein the first group of optical fibers is vertically positioned between the first region and the second group of optical fibers, wherein each optical fiber in the second group of optical fibers contacts the first group of optical fibers, and wherein the second group of optical fibers is positioned against the first group of optical fibers by applying a force to the second group of optical fibers through the first fastener.

18. The optical fiber array unit according to claim 16, the optical fiber array unit further comprising: a second group of optical fibers, wherein the first group of optical fibers is vertically positioned between the first region and the second group of optical fibers, wherein each optical fiber in the second group of optical fibers contacts the first group of optical fibers, and wherein the second group of optical fibers is positioned against the first group of optical fibers by applying a force to the second group of optical fibers through a second fastener.

19. The optical fiber array unit according to claim 12, wherein after positioning the first group of optical fibers, the first fastener is fixed relative to the optical fiber array structure.

20. The optical fiber array unit according to any one of claims 1, 2 or 7, wherein the first group of optical fibers, the first guiding member and the second guiding member each have a circular cross-section.

21. A method of manufacturing an optical fiber array unit, the method comprising: Providing a first group of optical fibers, a first guiding member, and a second guiding member; Providing an optical fiber array structure having a surface that defines a first groove and a second groove, the surface defining a first region between the first groove and the second groove, wherein the first region is configured to be free of any grooves; Positioning the first guiding member in the first groove; Positioning the second guiding member in the second groove; Positioning the first group of optical fibers such that each optical fiber in the first group of optical fibers contacts the first region to be positioned between the first guiding member and the second guiding member; And Fixing the first group of optical fibers relative to the optical fiber array structure.

22. The method according to claim 21, wherein the first group of optical fibers is fixed relative to the optical fiber array structure by laser welding or by an adhesive.

23. The method according to claim 21, wherein a first fastener is used to assist in positioning the first guiding member in the first groove and to assist in positioning the second guiding member in the second groove.

24. The method according to claim 21, the method further comprising: Providing a first fastener; And Positioning the first group of optical fibers by applying a force to the first group of optical fibers through the first fastener.

25. The method according to claim 21, the method further comprising: Providing a second group of optical fibers; Positioning the second group of optical fibers such that the first group of optical fibers is vertically positioned between the first region and the second group of optical fibers; And Fixing the second group of optical fibers relative to the optical fiber array structure.

26. An optical fiber array unit, the optical fiber array unit comprising: A first group of optical fibers; A first guiding member and a second guiding member; And An optical fiber array structure having a surface, wherein the surface is configured to be free of any grooves, Wherein the first guiding member is positioned at a first position on the surface, wherein the second guiding member is positioned at a second position on the surface, and wherein each optical fiber in the first group of optical fibers is positioned between the first guiding member and the second guiding member.

27. The optical fiber array unit according to claim 26, wherein the first guiding member is positioned at the first position by applying a force to the first guiding member through a first fastener, wherein the first fastener defines a first groove, wherein the first groove is configured to at least partially receive the first guiding member to assist in positioning the first guiding member at the first position, wherein the second guiding member is positioned at the second position by applying a force to the second guiding member through the first fastener, wherein the first fastener defines a second groove, wherein the second groove is configured to at least partially receive the second guiding member to assist in positioning the second guiding member at the second position.

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