Core spacing control in optical fiber array

Abstract

The present disclosure provides a system having an optical fiber array structure having a first portion and a second portion. The first portion has a first surface with a first set of grooves. The second portion has a second surface with a second set of grooves including end grooves and additional grooves between the end grooves. A first fiber array is located within the first set of grooves. A second optical fiber array is located within the second set of grooves. The first portion is positioned adjacent to the second portion such that the first surface faces the second surface and such that the grooves extend parallel to each other. A first spacer is disposed between the arrays of optical fibers. A first dummy fiber is disposed in the end groove and helps maintain a rotational orientation and / or position of the first spacer relative to the first array of fibers.

Description

[0001] Cross - reference to related applications

[0002] This application claims priority to U.S. Application No. 63 / 423,524, filed on Nov. 8, 2022, the entire content of which is incorporated herein by reference. Technical Field

[0003] Embodiments of the present disclosure generally relate to using contact features, such as dummy optical fibers, to assist in controlling the rotational orientation and / or position of optical fibers within an optical fiber array structure. Background Art

[0004] Two - dimensional optical fiber arrays have been used to create high - fiber - density optical interconnections for high - density applications in optical communication. These optical fiber arrays are beneficial because they permit high fiber density, thereby allowing for a reduction in the overall footprint of electrical components. However, as the fiber density increases, it is often challenging to maintain the proper position and orientation of the optical fibers. Failure to maintain the proper fiber position makes the optical fibers less effective, and failure to maintain the proper orientation of the optical fibers generally makes optical fibers, such as polarization - maintaining optical fibers and multi - core optical fibers, less effective. Summary of the Invention

[0005] In various embodiments, contact features, such as dummy optical fibers, are provided to assist in controlling the rotational orientation and / or position of optical fibers in an optical fiber array structure. An optical fiber array structure may be provided such that one or more spacers are disposed between a first optical fiber array and a second optical fiber array, where the spacers contact the first optical fiber array and the second optical fiber array. The contact features contact the spacers to assist in controlling the rotational orientation and / or position of the spacers. By doing so, the spacers are maintained in the proper orientation and / or position, and this prevents the optical fibers in the optical fiber array from moving away from their proper orientation and / or position. By keeping the optical fibers in their correct orientation and / or position, it can be better ensured that the optical fibers operate properly and are free of defects.

[0006] The first optical fiber array is disposed in a first set of grooves, and the second optical fiber array is disposed in a second set of grooves. In the case of using dummy optical fibers, additional end grooves may be provided at each end of a set of grooves, and each dummy optical fiber may be at least partially received within one of the additional end grooves. The dummy optical fiber extends out of the additional end groove until the dummy optical fiber contacts the spacer, and this contact helps prevent unnecessary deviation from the proper orientation and / or position of the spacer. Notably, the positioning and orientation of the spacer affect the relative position and orientation of various components (such as other optical fibers and other parts of the optical fiber array structure), so it is important to maintain the spacer in the proper orientation and position.

[0007] In the case of using polarization-maintaining optical fibers or multi-core optical fibers, it is particularly important to maintain the optical fibers in an appropriate orientation. In addition, while a dummy optical fiber is an example of a contact feature, the contact feature can be some other object attachable to the optical fiber array structure, or the contact feature can be integral with a portion of the optical fiber array structure.

[0008] In an example embodiment, a system for improving optical fiber positioning is provided. The system includes an optical fiber array structure having a first portion and a second portion. The first portion has a first surface in which a first set of grooves is defined. The second portion has a second surface in which a second set of grooves is defined, and the second set of grooves includes a first end groove, a second end groove, and one or more additional grooves between the first end groove and the second end groove. The system also includes a first optical fiber array, and each optical fiber in the first optical fiber array is located within a groove in the first set of grooves. In addition, the system includes a second optical fiber array, and each optical fiber in the second optical fiber array is located within a groove in the second set of grooves. The system also includes a first spacer and a first dummy optical fiber. The first portion of the optical fiber array structure is configured to be placed adjacent to the second portion of the optical fiber array structure such that the first surface of the first portion faces the second surface of the second portion and such that the first set of grooves extends parallel to the second set of grooves. The first spacer is disposed between the first optical fiber array and the second optical fiber array. In addition, the first dummy optical fiber is disposed in one of the first end groove or the second end groove, and the first dummy optical fiber is configured to assist in maintaining the rotational orientation and / or position of the first spacer relative to at least the first optical fiber array.

[0009] In some embodiments, the first dummy optical fiber can be configured to contact the first spacer when assembling the system. Additionally, in some embodiments, the first spacer can be configured to contact each of the optical fibers in the first optical fiber array and the second optical fiber array when the first optical fiber array is received in the first set of grooves and when the second optical fiber array is received in the second set of grooves. Further, in some embodiments, the first dummy optical fiber can be configured to assist in maintaining the rotational orientation and / or position of at least one optical fiber in the first optical fiber array or the second optical fiber array.

[0010] In some embodiments, the first dummy optical fiber may be configured to contact the first spacer to assist in maintaining the rotational orientation and / or position of the first spacer. The contact between the first dummy optical fiber and the first spacer may cause the first spacer to contact an optical fiber in the first optical fiber array or the second optical fiber array such that the optical fiber may be held in a proper rotational orientation and / or proper position within a groove in the first set of grooves or the second set of grooves. Additionally, in some embodiments, the first dummy optical fiber may be configured to assist in controlling the orientation of the optical fibers in the first optical fiber array or the second optical fiber array. Further, in some embodiments, the optical fibers within the first optical fiber array or the second optical fiber array may be polarization-maintaining optical fibers or multi-core optical fibers. Additionally, in some embodiments, the system may further include a second dummy optical fiber. In such a case, the first dummy optical fiber may be disposed in the first end groove, and the second dummy optical fiber may be disposed in the second end groove. In some embodiments, the optical fibers in the first optical fiber array or the second optical fiber array may be optical waveguides.

[0011] In some embodiments, the first optical fiber array and the second optical fiber array may extend in a first direction, the first spacer may extend in a second direction, and the second direction may be perpendicular to the first direction. In some embodiments, each groove in the first set of grooves and the second set of grooves may extend in a length direction. The first set of grooves may be aligned in a transverse direction perpendicular to the length direction, and the second set of grooves may be aligned in the transverse direction. Additionally, the first portion and the second portion may be positioned relative to each other such that the first set of grooves and the second set of grooves are offset from each other in the transverse direction.

[0012] In some embodiments, the system may further include one or more additional spacers. The first spacer and the additional spacers may be disposed between the first optical fiber array and the second optical fiber array, and the first dummy optical fiber may be configured to assist in controlling the rotational orientation and / or position of the first spacer and the additional spacers.

[0013] In some embodiments, the second portion may have an opposing surface opposite the second surface. Additionally, the fiber optic array structure may further include a third portion, a third fiber optic array, and a second spacer. The third portion may have a third surface in which a third set of grooves is defined, and each fiber in the third fiber optic array may be located within a groove in the third set of grooves. The second portion of the fiber optic array structure may be configured to be located between the first portion and the third portion of the fiber optic array structure, and the second portion of the fiber optic array structure may be configured to be placed adjacent to the third portion of the fiber optic array structure such that the opposing surface of the second portion faces the third surface of the third portion and such that the second set of grooves extends parallel to the third set of grooves. The second spacer may be disposed between the second fiber optic array and the third fiber optic array. Additionally, the first dummy fiber may be configured to help maintain the rotational orientation and / or position of the first spacer relative to at least the first fiber optic array, and the first dummy fiber may be configured to help maintain the rotational orientation and / or position of the second spacer relative to at least the third fiber optic array. Additionally, in some embodiments, the second spacer may include the second portion.

[0014] In another exemplary embodiment, there is provided a fiber optic array unit for improving fiber optic positioning. The fiber optic array unit includes a fiber optic array structure having a first portion and a second portion. The first portion has a first surface in which a first set of grooves is defined, and each groove in the first set of grooves is configured to receive a fiber in a first fiber optic array. The second portion has a second surface in which a second set of grooves is defined, and each groove in the second set of grooves is configured to receive a fiber in a second fiber optic array. The second set of grooves includes a first end groove, a second end groove, and one or more additional grooves between the first end groove and the second end groove. The first portion of the fiber optic array structure is configured to be placed adjacent to the second portion of the fiber optic array structure such that the first surface of the first portion faces the second surface of the second portion and such that the first set of grooves extends parallel to the second set of grooves. Additionally, the fiber optic array unit is configured to receive a spacer between the first fiber optic array and the second fiber optic array. The first end groove and / or the second end groove is configured to receive a first dummy fiber, and the first dummy fiber helps maintain the rotational orientation and / or position of the spacer relative to at least the first fiber optic array.

[0015] In another example embodiment, a method for manufacturing a system for improving fiber optic positioning is provided. The method includes providing a fiber optic array structure, where the fiber optic array structure has a first portion and a second portion. The first portion has a first surface in which a first set of grooves is defined. Additionally, the second portion has a second surface in which a second set of grooves is defined, and the second set of grooves includes a first end groove, a second end groove, and one or more additional grooves between the first end groove and the second end groove. The method further includes providing a first fiber optic array, a second fiber optic array, a spacer, and a first dummy fiber. Additionally, the method includes positioning each fiber in the first fiber optic array within a groove in the first set of grooves, positioning each fiber in the second fiber optic array within a groove in the second set of grooves, and positioning the spacer between the first fiber optic array and the second fiber optic array. Further, the method includes positioning the first dummy fiber in one of the first end groove or the second end groove, where the first dummy fiber helps maintain the rotational orientation and / or position of the spacer relative to at least the first fiber optic array. The method also includes positioning the first portion of the fiber optic array structure adjacent to the second portion of the fiber optic array structure such that the first surface of the first portion faces the second surface of the second portion and such that the first set of grooves extends parallel to the second set of grooves.

[0016] In another example embodiment, a system for improving fiber optic positioning is provided. The system includes a fiber optic array structure that includes a first portion and a second portion. The first portion has a first surface in which a first set of grooves is defined, and the second portion has a second surface in which a second set of grooves is defined. The system also includes a first fiber optic array and a second fiber optic array. Each fiber in the first fiber optic array is located within a groove in the first set of grooves, and each fiber in the second fiber optic array is located within a groove in the second set of grooves. The system also includes a spacer and a contact feature. The first portion of the fiber optic array structure is configured to be placed adjacent to the second portion of the fiber optic array structure such that the first surface of the first portion faces the second surface of the second portion and such that the first set of grooves extends parallel to the second set of grooves. The spacer is disposed between the first fiber optic array and the second fiber optic array. The contact feature is disposed at the second surface of the second portion, adjacent to the second set of grooves, and the contact feature is configured to help maintain the rotational orientation and / or position of the spacer relative to at least the second fiber optic array.

[0017] In some embodiments, the contact feature may be configured to contact the spacer when assembling the system. In some embodiments, the spacer may be configured to contact each of the optical fibers in the first and second optical fiber arrays when the first optical fiber array is received in the first set of grooves and when the second optical fiber array is received in the second set of grooves.

[0018] In some embodiments, the contact feature may be integral with the second portion of the optical fiber array structure, and when the contact feature is integral with the second portion, the contact feature may protrude from the second surface of the second portion of the optical fiber array structure. In some embodiments, the contact feature may be an object that is not integral with the second portion of the optical fiber array structure. Additionally, the second set of grooves may include a first end groove, a second end groove, and one or more additional grooves between the first end groove and the second end groove. The contact feature may be received in the first end groove or the second end groove and protrude beyond the second surface of the second portion of the optical fiber array structure.

[0019] In some embodiments, the contact feature may be configured to help maintain the rotational orientation and / or position of at least one optical fiber in the first optical fiber array or the second optical fiber array. In some embodiments, the contact feature may be configured to contact the spacer to help maintain the rotational orientation and / or position of the spacer. The contact between the contact feature and the spacer may cause the spacer to contact the optical fibers in the first optical fiber array or the second optical fiber array such that the optical fibers may be held in a proper rotational orientation and / or proper position within the grooves in the first set of grooves or the second set of grooves. Additionally, in some embodiments, the contact feature may be configured to help control the orientation of the optical fibers in the first optical fiber array or the second optical fiber array.

[0020] In another exemplary embodiment, an optical fiber array unit for improving optical fiber positioning is provided. The optical fiber array unit has an optical fiber array structure including a first portion and a second portion. The first portion has a first surface in which a first set of grooves is defined, and each groove in the first set of grooves is configured to receive an optical fiber in a first optical fiber array. The second portion has a second surface in which a second set of grooves is defined, and each groove in the second set of grooves is configured to receive an optical fiber in a second optical fiber array. The optical fiber array unit further includes a spacer and a contact feature. The first portion of the optical fiber array structure is configured to be placed adjacent to the second portion of the optical fiber array structure such that the first surface of the first portion faces the second surface of the second portion and such that the first set of grooves extends parallel to the second set of grooves. The optical fiber array unit is configured to receive the spacer between the first optical fiber array and the second optical fiber array. The contact feature is provided at the second surface of the second portion, adjacent to the second set of grooves, and the contact feature is configured to assist in maintaining the rotational orientation and / or position of the spacer relative to at least the second optical fiber array. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Reference will now be made to the drawings, which are not necessarily to scale, and in which:

[0022] Figure 1A is a perspective view showing an exemplary two-dimensional optical fiber array structure in accordance with some embodiments discussed herein;

[0023] Figure 1B is showing in accordance with some embodiments discussed herein Figure 1A an exploded view of an exemplary two-dimensional optical fiber array structure;

[0024] Figure 2 is a cross-sectional view showing an exemplary two-dimensional optical fiber array structure and the optical fibers provided therein in accordance with some embodiments discussed herein;

[0025] Figure 3A is showing in accordance with some embodiments discussed herein Figure 2 a side cross-sectional view of an exemplary two-dimensional optical fiber array structure;

[0026] Figure 3B is showing in accordance with some embodiments discussed herein Figure 3A an enhanced cross-sectional view of an exemplary two-dimensional optical fiber array structure;

[0027] Figure 4A is a cross-sectional view showing an exemplary two-dimensional optical fiber array structure having dummy optical fibers therein in accordance with some embodiments discussed herein;

[0028] Figure 4B is an enhanced cross-sectional view of an exemplary two-dimensional optical fiber array structure according to some embodiments discussed herein Figure 4A in which dummy optical fibers can be more easily seen;

[0029] Figure 4C is a cross-sectional view of an exemplary two-dimensional optical fiber array structure having contact features according to some embodiments discussed herein;

[0030] Figure 4D is an enhanced cross-sectional view of an exemplary two-dimensional optical fiber array structure according to some embodiments discussed herein Figure 4C in which contact features can be more easily seen;

[0031] Figure 5 is a cross-sectional view of an exemplary optical fiber array structure for housing two optical fiber arrays according to some embodiments discussed herein;

[0032] Figure 6 is a cross-sectional view of an exemplary optical fiber array structure for housing three optical fiber arrays according to some embodiments discussed herein;

[0033] Figure 7 is a perspective view of an exemplary optical fiber according to some embodiments discussed herein; and

[0034] Figure 8 is a flowchart of an exemplary method for manufacturing an optical fiber array structure or system according to some embodiments discussed herein. DETAILED DESCRIPTION

[0035] Example embodiments of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments are shown. In fact, 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. Like reference numerals generally refer to like elements throughout. For example, reference numerals 124A, 324A, 424A, etc. are each intended to refer to a spacer. Additionally, unless otherwise specifically stated, any connection or attachment can be a direct or indirect connection or attachment. Although the positioning of certain components is described below based on the orientation presented in the associated drawings, the positioning of these components can change in the event of a change in the orientation of the optical fiber array structure or other components. For example, although a first portion may be shown and described herein as being disposed below a second portion, it is contemplated that the optical fiber array structure may be disposed in other orientations such that the first portion and the second portion have different positions relative to each other.

[0036] Figure 1A is a perspective view showing an exemplary two-dimensional optical fiber array structure 100, andFigure 1B It is shown Figure 1A 1 is an exploded view of an example two-dimensional optical fiber array structure 100, in which certain individual components can be more easily seen. The optical fiber array structure 100 includes a first portion 102 and a second portion 104 that can be disposed adjacent to the first portion 102. In the illustrated embodiment, the second portion 104 is disposed above the first portion 102, but in other embodiments, the relative orientation of the two portions can be changed. The first portion 102 includes a first surface 106, and a first set of grooves 108 are defined in the first surface 106. In addition, the second portion 104 includes a second surface 110 (see Figure 1B ), and the second set of grooves 112 (see Figure 1B ) is defined in the second surface 110. Except for the grooves defined in the first surface 106 and the second surface 110, the two surfaces may have a generally flat shape. The grooves may be formed by high-precision machining. The shape and size of the first group of grooves 108 may affect the rotational orientation and / or position of the first optical fiber array 118 in the X direction, the Y direction, and the Z direction, and the shape and size of the first group of grooves 108 may indirectly affect the rotational orientation and / or position of the spacer 124A. Similarly, the shape and size of the second group of grooves 112 may affect the rotational orientation and / or position of the second optical fiber array 120 in the X direction, the Y direction, and the Z direction, and the shape and size of the second group of grooves 112 may indirectly affect the rotational orientation and / or position of the spacer 124A.

[0037] like Figure 1A As shown in , an optical fiber array is provided, and each of these optical fibers is partially housed in a groove within the optical fiber array structure 100. For example, a first coated optical fiber array 118A may be provided. The first coated optical fiber array 118A provides optical fibers having an optical fiber core coated with one or more layers of coating. Some or all of this coating may be removed to expose the optical fiber core within the first coated optical fiber array 118A. The first optical fiber array 118 may consist of uncoated optical fiber cores. The first optical fiber array 118 may be partially housed in a first group of grooves 108 in the first surface 106 of the first portion 102 of the optical fiber array structure 100. In addition, a second coated optical fiber array 120A is provided. The second coated optical fiber array 120A provides optical fibers coated with one or more layers of coating. Some or all of this coating may be removed to expose the optical fiber core within the second coated optical fiber array 120A. The second optical fiber array 120 may consist of uncoated optical fiber cores. The second optical fiber array 120 may be partially received in the second set of grooves 112 in the second surface 110 of the first portion 102 of the optical fiber array structure 100. Although the first optical fiber array 118 and the second optical fiber array 120 are shown as being partially coated, in other embodiments, these optical fiber arrays may be coated over their entire lengths, or these optical fiber arrays may be provided without any coating at all.

[0038] Each of the first portion 102 and the second portion 104 includes an outer groove 114. Although the first set of grooves 108 and the second set of grooves 112 are generally grouped together, the outer grooves 114 may be provided away from these other sets of grooves. In the illustrated embodiment, the outer grooves 114 are provided near the sides of the first portion 102 and the second portion 104. Each of the outer grooves 114 is configured to receive a portion of the positioning optical fiber 122. By doing so, it can be ensured that the first portion 102 and the second portion 104 are correctly positioned relative to each other along the Z axis. This can be beneficial to ensure that the first set of grooves 108 and the second set of grooves 112 are properly positioned relative to each other. In Figure 1A and 1B the illustrated embodiment, the first set of grooves 108 and the second set of grooves 112 extend in a first direction parallel to the Y axis. However, in other embodiments, the orientation of the optical fiber array structure 100 may be changed. Although the positioning optical fiber 122 is shown as being uncoated in some portions and coated in other portions, in other embodiments, the positioning optical fiber 122 may have a coating over its entire length, or the positioning optical fiber 122 may be provided without any coating at all.

[0039] Additionally, each of the first portion 102 and the second portion 104 includes a lateral groove 116. In the illustrated embodiment, the lateral grooves 116 extend in a second direction parallel to the Z axis. In this way, the direction of the lateral grooves 116 is perpendicular to the direction of the first set of grooves 108 and the direction of the second set of grooves 112. A spacer layer 124 may be disposed between the first surface 106 of the first portion 102 and the second surface 110 of the second portion 104. The spacer layer 124 may include one or more spacers 124A, and the spacers 124A may be in the form of optical fibers, sheets, or some other object. In the illustrated embodiment, the spacers 124A are in the form of optical fibers. The spacers 124A have a uniform cross-section in the X-Y plane along the Z direction, but in some embodiments, notches or deviations in the cross-section may be provided at certain positions along the Z direction. The spacers 124A may be configured to rest between the first optical fiber array 118 and the second optical fiber array 120. Each of the lateral grooves 116 is configured to receive a portion of the spacers 124A, and the lateral grooves 116 are configured to limit the movement of the first portion 102 and the second portion 104 relative to each other along the Y axis. For example, in Figure 1B the illustrated embodiment, the spacers 124A are provided in the form of optical fibers, and each lateral groove 116 is configured to receive a portion of the spacers 124A.

[0040] Other features of the optical fiber array structure are in Figure 2is shown in the schematic cross-sectional view. As shown, the fiber optic array structure 200 is provided with a first portion 202 and a second portion 204. This cross-section is relative to Figures 1A to 1B the fiber optic array structure 100 shown extends in the X-Y plane. Each optical fiber in the first fiber optic array 218 can be partially received in a groove in the first set of grooves 108 of the first portion 202 (see Figure 1B ), and each optical fiber in the second fiber optic array 220 can be partially received in a groove in the second set of grooves 112 of the second portion 204 (see Figure 1B ). The spacer layer 224 includes one or more spacers 124A (see Figure 1B ). The spacer layer 224 is disposed between the first portion 202 and the second portion 204 such that the spacer layer 224 is positioned between the first fiber optic array 218 and the second fiber optic array 220. The first fiber optic array 218 may have a cladding portion such that a first clad fiber optic array 218A is provided, and the second fiber optic array 220 may also have a cladding portion such that a second clad fiber optic array 220A is provided. In some embodiments, the first clad fiber optic array 218A and the second clad fiber optic array 220A may each be received in a fiber ribbon 228 to further protect and organize the optical fibers in the array. Additionally, once the relevant components are assembled, an epoxy 226 may be added to at least partially restrict the movement of the optical fibers and other components. In some embodiments, the optical fibers in the first fiber optic array 218 and the second fiber optic array 220 may be optical waveguides, but other types of optical fibers may be used. In some embodiments, the optical waveguides may be polarization-maintaining optical waveguides or multi-core optical fibers.

[0041] Although Figure 2 a cross-sectional view with respect to the X-Y axes is provided, Figure 3A another cross-sectional view with respect to the X-Z axis is shown. As shown, the fiber optic array structure 300 includes a first portion 302 and a second portion 304, where the first portion 302 has a first set of grooves 308 and where the second portion 304 has a second set of grooves 312. Additionally, each of the first portion 302 and the second portion 304 includes an outer groove 314, where the outer groove 314 is configured to receive a positioning optical fiber 322 to assist in positioning the first portion 302 and the second portion 304 relative to each other in the Z direction. As shown, the first set of grooves 308 and the second set of grooves 312 are offset from each other in the Z direction, where each groove in the first set of grooves 308 is generally positioned between two grooves in the second set of grooves 312 in the Z direction. Similarly, each groove in the second set of grooves 312 is generally positioned between two grooves in the first set of grooves 308 in the Z direction.

[0042] A first fiber optic array 318 and a second fiber optic array 320 are also provided. Each fiber of the first fiber optic array 318 can be at least partially received within a groove of the first set of grooves 308, and each fiber of the second fiber optic array 320 can be at least partially received within a groove of the second set of grooves 312. One or more spacers 324A can be disposed between the first fiber optic array 318 and the second fiber optic array 320. The spacer 324A is configured to contact each fiber of the first fiber optic array 318, and the spacer 324A is configured to contact each fiber of the second fiber optic array 320. In this way, the spacer 324A can help control the rotational orientation of the fibers and the positioning of the fibers (e.g., in the X direction, Y direction, Z direction, etc.).

[0043] Controlling the position and rotational orientation of the fibers and spacers is an important consideration. If the position or rotational orientation of the fibers is incorrect, then this may prevent the fibers from functioning properly. For certain types of fibers, such as polarization maintaining optical fibers or multi-core fibers, properly maintaining the rotational orientation of the fibers is particularly important. Additionally, if the position or rotational orientation of the spacers is incorrect, then this may indirectly affect the positioning or rotational orientation of other components such as the first fiber optic array 318, the second fiber optic array 320, the first portion 302, or the second portion 304.

[0044] As Figure 3A shown, the first set of grooves 312 and the second set of grooves 308 are offset from each other in the Z direction, and this offset may generally result in incorrect positioning of the spacer 324A, the fibers of the first fiber optic array 318, or the fibers of the second fiber optic array 320. This problem is most clearly shown in the enhanced view of Figure 3B . As Figure 3A and 3B shown, the spacer 324A generally extends in the Z direction along the left hand side of the spacer 324A in the figure. However, when the spacer 324A extends to the right and past the last fiber 320' in the second fiber optic array 320, the spacer 324A begins to extend in different directions with respect to the vertical element in the X direction (which may occur during manufacturing and / or over time). As Figure 3B shown, the position of the spacer 324A in the X direction at the last fiber 318' in the first fiber optic array 318 is offset by a distance (B) from the position of the spacer 324 in the X direction at the last fiber 320' in the second fiber optic array 320. This distance (B) can take on a wide variety of values. For example, in some embodiments, the distance (B) can be in the range from zero to ten (10) microns, from zero to eight (8) microns, from zero to five (5) microns, or from one (1) micron to three (3) microns. Since there are no additional fibers or objects passing through Figure 3Bthe last optical fiber 320' of the second optical fiber array 320 as shown, the spacer 324A can be shifted along the X-axis and can be deformed in size or shape. As an indirect result of such deformation, it may be permitted that the last optical fiber 318' on the rightmost side of the first optical fiber array 318 rotates more freely within the groove and may also be permitted to move its position within the groove. These undesirable variations in the positioning of the last optical fiber 318' may cause the last optical fiber 318' to be less effective, and thus a solution for better controlling the rotational orientation and position of the optical fibers and spacers is desired. Although this example only shows the deformation of the rotational orientation and position of the spacer 324A on the right side of the spacer 324A, in Figure 3B deformation may occur on the left side of the spacer 324A.

[0045] Figure 3B The gap between the spacer 324A and the second part 304 is also shown, where the spacer 324A and the second part 304 are separated by a distance (A). In some embodiments, the distance (A) can vary, and the distance (A) can depend on the cross-sectional size of the optical fiber (or the diameter of the optical fiber in the case where the optical fiber has a circular cross-section), the shape of the groove, and the cross-sectional size of the spacer (or the diameter of the spacer in the case where the spacer has a circular cross-section). In some embodiments, it may be beneficial to provide the assembly such that the distance (A) is a non-zero value. This may be beneficial for accommodating defects within the shape of the first part 302 or the second part 304. In the illustrated embodiment, the distance (A) is thirty (30) microns, but the distance (A) can have other values. The gap between the spacer 324A and the first part 302 can be defined by the distance (A).

[0046] Figure 4A and 4B The embodiment shown in Figure 3A and 3B is similar to the embodiment shown in Figure 3A and 3B , but introduces contact features, such as dummy optical fibers, to better control the rotational orientation and position of the spacers and optical fibers. The contact features can help provide a more uniform force acting on the spacers in certain critical parts such that the optical fibers are properly positioned and oriented. It is noted that while some embodiments show dummy optical fibers being used as contact features, other objects (e.g., rods, balls, objects of other shapes, protrusions, or other surface features) can also be envisioned. It is noted that such contact features engage the spacers at appropriate positions (e.g., after the last optical fiber in a group of optical fibers) to maintain the desired relative orientation and / or position of the spacers with respect to the optical fibers.

[0047] Figure 4A is a cross-sectional view showing an example two-dimensional optical fiber array structure having dummy optical fibers therein. Figure 4B is showing Figure 4AEnhanced cross-sectional view of an exemplary two-dimensional fiber optic array structure, where dummy fibers can be more easily seen. Similar to Figure 3A and 3B In an embodiment, the fiber optic array structure 400 has a first portion 402 and a second portion 404, where the first portion 402 has a first set of grooves 408 and the second portion 404 has a second set of grooves 412. Each fiber of the first fiber optic array 418 is partially received in a corresponding groove of the first set of grooves 408, and each fiber of the second fiber optic array 420 is partially received in a corresponding groove of the second set of grooves 412. Outer grooves 414 are provided in each of the first portion 402 and the second portion 404, and the outer grooves 414 are configured to receive positioning fibers 422 such that the first portion 402 and the second portion 404 can be properly positioned relative to each other. A spacer 424A is also provided between the first fiber optic array 418 and the second fiber optic array 420.

[0048] Relative to Figure 3A and 3B In the example shown in Figure 4A and 4B In an embodiment, improvements have been made to help control the rotational orientation and position of the optical fibers and spacers. In the illustrated embodiment, a first end groove 412A and a second end groove 412B are added to the second set of grooves 412. The first end groove 412A of the second set of grooves 412 is provided outside each other groove of the first set of grooves 408 in the negative Z direction. In addition, the second end groove 412B of the second set of grooves 412 is provided outside each other groove of the first set of grooves 408 in the positive Z direction.

[0049] The first end groove 412A is configured to partially receive a first dummy fiber 428A, and the second end groove 412B is configured to partially receive a second dummy fiber 428B. The first dummy fiber 428A and the second dummy fiber 428B are configured to protrude outward from their respective grooves to contact one or more spacers 424A. By doing so, the first dummy fiber 428A and the second dummy fiber 428B can help maintain the proper rotational orientation and position of the spacer 424A. In addition, the contact between the corresponding dummy fiber and the spacer 424A holds the fibers of the first fiber optic array 418 in their proper rotational orientation and position in their respective grooves. For example, see Figure 4B , the second dummy fiber 428B contacts the spacer 424A to push the spacer 424A downward, which causes the spacer 424A to contact the last fiber 418' in the first fiber optic array 418 (see 4A). This contact with the last fiber 418' in the first fiber optic array 418 (see 4A) ensures that the last fiber 418' maintains its proper rotational orientation and position. Although in Figure 3BThe distance (B) is shown as the position offset of the spacer in the X direction, but the use of dummy optical fibers minimizes this distance (B) and can approximate this distance (B) to zero. Although the first end groove 412A and the second end groove 412B are shown as part of the second set of grooves 412, in other embodiments, the first end groove 412A and the second end groove 412B may be provided in the first set of grooves 408.

[0050] Figures 4C to 4D An optical fiber array structure is shown using contact features configured to hold the positioning and / or orientation of the spacer. Figure 4C A cross-sectional view of an exemplary two-dimensional optical fiber array structure 400' having such contact features is shown, and Figure 4D is an enhanced cross-sectional view that allows Figure 4C the contact features to be more readily seen.

[0051] Similar to Figure 4A and 4B 's embodiments, the optical fiber array structure 400' has a first portion 402' and a second portion 404', where the first portion 402' has a first set of grooves 408' and the second portion 404' has a second set of grooves 412'. Each optical fiber in the first optical fiber array 418 is partially received in a corresponding groove in the first set of grooves 408', and each optical fiber in the second optical fiber array 420 is partially received in a corresponding groove in the second set of grooves 412'. A spacer 424A is also provided between the first optical fiber array 418 and the second optical fiber array 420.

[0052] In Figure 4C and 4DIn the optical fiber array structure 400', the first part 402' has a first contact feature 429A and a second contact feature 429B, where both the first contact feature 429A and the second contact feature 429B are integral with the first part 402'. Both the first contact feature 429A and the second contact feature 429B are configured to protrude from the first part 402' to contact the spacer 424A. Additionally, the second part 404' has a third contact feature 429C and a fourth contact feature 429D, where both the third contact feature 429C and the fourth contact feature 429D are integral with the second part 404'. Both the third contact feature 429C and the fourth contact feature 429D are configured to protrude from the second part 404' to contact the spacer 424A. The first contact feature 429A and the third contact feature 429C can contact the spacer 424A at the first end of the spacer 424A on the left side, and these contact features help restrict rotational movement of the spacer 424A and / or movement in the X, Y, and / or Z directions. Similarly, the second contact feature 429B and the fourth contact feature 429D can contact the spacer 424A at the second end of the spacer 424A on the right side, and these contact features can help restrict rotational movement of the spacer 424A and / or movement in the X, Y, and / or Z directions. In some embodiments, the contact features can protrude outward in a shape generally conforming to that of a rectangular prism, but in other embodiments, the shape of the contact features can be different. For example, the contact features can have curvature or can have a geometry that partially encloses the spacer in the Y direction.

[0053] In some embodiments, dummy optical fibers can be disposed at other locations to further ensure maintaining proper rotational orientation and position of the spacer and other optical fibers. Figure 5 Another example of the dummy optical fibers used is shown. Figure 5 is a cross-sectional view showing an example optical fiber array structure for accommodating two optical fiber arrays.

[0054] Figure 5 The embodiment shown in Figure 4A and 4B is similar to the embodiment shown in Figure 5 is a cross-sectional view showing an example two-dimensional optical fiber array structure 500 having dummy optical fibers. Similar to Figure 4A and 4BIn an embodiment, a first portion 502 and a second portion 504 are provided, where the first portion 502 has a first set of grooves 508 and the second portion 504 has a second set of grooves 512. Each optical fiber in the first optical fiber array 518 is partially received in a corresponding groove in the first set of grooves 508, and each optical fiber in the second optical fiber array 520 is partially received in a corresponding groove in the second set of grooves 512. Outer grooves 514 are provided in each of the first portion 502 and the second portion 504, and the outer grooves 514 are configured to receive and position the optical fiber 522 such that the first portion 502 and the second portion 504 are properly positioned relative to each other. A spacer 524A is also provided between the first optical fiber array 518 and the second optical fiber array 520.

[0055] In addition, in Figure 5 the first set of grooves 508 includes a first end groove 508A and a second end groove 508B, and additional grooves in the first set of grooves 508 are provided between the first end groove 508A and the second end groove 508B. The second set of grooves 512 includes a first end groove 512A and a second end groove 512B, and additional grooves in the second set of grooves 512 are provided between the first end groove 512A and the second end groove 512B.

[0056] Dummy optical fibers are partially received in some or all of the end grooves. For example, in Figure 5 the illustrated embodiment, a first end groove 512A of the second set of grooves 512 receives a portion of a first dummy optical fiber 528A, a second end groove 512B of the second set of grooves 512 receives a portion of a second dummy optical fiber 528B, a first end groove 508A of the first set of grooves 508 receives a portion of a third dummy optical fiber 528C therein, and a second end groove 508B of the first set of grooves 508 receives a portion of a fourth dummy optical fiber 528D therein. By providing the dummy optical fibers, it is better ensured that the spacer 524A and additional optical fibers extending between the end optical fibers are set with proper rotational orientation and position.

[0057] In some embodiments, an optical fiber array structure configured to receive and control the positioning of three or more optical fiber arrays may be provided. Figure 6FIG. 0 is a cross-sectional view showing an exemplary fiber optic array structure 600 for accommodating three fiber optic arrays. The fiber optic array structure 600 includes a first portion 602, a second portion 604, and a third portion 605. A first set of grooves 608 is defined in a first surface 606 of the first portion 602, and each groove in the first set of grooves 608 is configured to accommodate a portion of the fibers of the first fiber optic array 618. A second set of grooves 612 is defined in a second surface 610 of the second portion 604, and the second set of grooves 612 extends from the second surface 610 to an opposite surface 611 of the second portion 604. Each groove in the second set of grooves 612 is configured to accommodate a portion of the fibers of the second fiber optic array 620. Additionally, a third set of grooves 613 is defined in a third surface 615 of the third portion 605, and each groove in the third set of grooves 613 is configured to accommodate a portion of the fibers of the third fiber optic array 621. One or more first spacers 624A are disposed between the first portion 602 and the second portion 604 such that the first spacer 624A rests between the first fiber optic array 618 and the second fiber optic array 620. Further, one or more second spacers 624B are disposed between the second portion 604 and the third portion 605 such that the second spacer 624B rests between the second fiber optic array 620 and the third fiber optic array 621.

[0058] Further, each of the first portion 602 and the second portion 604 has an outer groove 614A configured to accommodate a portion of a first positioning fiber 622A, and this first positioning fiber 622A helps maintain proper positioning of the first portion 602 and the second portion 604 relative to each other in the Z direction. Additionally, each of the second portion 604 and the third portion 605 has an outer groove 614B configured to partially accommodate a second positioning fiber 622B, and this second positioning fiber 622B helps maintain proper positioning of the second portion 604 and the third portion 605 relative to each other in the Z direction. When properly positioned, the second portion 604 of the fiber optic array structure is disposed adjacent to the third portion 605 of the fiber optic array structure such that the opposite surface 611 of the second portion 604 faces the third surface 615 of the third portion 605 and such that the second set of grooves 612 extends parallel to the third set of grooves 613.

[0059] In Figure 6 the illustrated embodiment of FIG. 8, the second set of grooves 612 is provided with a first end groove 612A and a second end groove 612B. The first end groove 612A of the second set of grooves 612 is disposed outside of each other groove in the first set of grooves 608 and the third set of grooves 613 in the negative Z direction. Additionally, the second end groove 612B of the second set of grooves 612 is disposed outside of each other groove in the first set of grooves 608 and the third set of grooves 613 in the positive Z direction.

[0060] The first dummy optical fiber 628A is partially received in the first end groove 612A of the second set of grooves 612, and the second dummy optical fiber 628B is partially received in the second end groove 612B of the second set of grooves 612. Both the first dummy optical fiber 628A and the second dummy optical fiber 628B are configured to help maintain the rotational orientation and / or position of the first spacer 624A relative to at least the first optical fiber array 618, and both the first dummy optical fiber 628A and the second dummy optical fiber 628B are configured to help maintain the rotational orientation and / or position of the second spacer 624B relative to at least the third optical fiber array 621.

[0061] In some embodiments, the second portion 604 may be integral with one of the spacers 624A, 624B. In some embodiments, one or more portions of the second portion 604 (such as the second set of grooves 612) may extend from one of the spacers. In such exemplary embodiments, only one positioning optical fiber may be required, and the first portion 602 may be adjacent to the third portion 605, where three optical fiber arrays are located in corresponding grooves and the spacer (the spacer having the second set of grooves) is located therebetween.

[0062] In some embodiments, the dummy optical fibers may generally have the same size and shape as other optical fibers in the first optical fiber array and the second optical fiber array. Additionally, the dummy optical fibers may include certain materials that are also disposed in the first optical fiber array and / or the second optical fiber array. However, in other embodiments, the dummy optical fibers may have different sizes, different shapes, or one or more different materials than other optical fibers in the first optical fiber array and the second optical fiber array. For example, in some embodiments, the dummy optical fibers may have a larger cross-sectional area (or a larger diameter in the case of using a circular cross-section) than the optical fibers in the first optical fiber array and the second optical fiber array. In some embodiments, the dummy optical fibers may include a material that is more deformable than the materials of the optical fibers in the first optical fiber array and the second optical fiber array, and the increased deformability of the material of the dummy optical fibers may permit a larger surface area of the dummy optical fibers to contact the spacer, such that the amount of friction between the dummy optical fibers and the spacer is increased. However, in other embodiments, the dummy optical fibers may include a material that is less deformable (e.g., more rigid) than the materials of the other optical fibers, which may help to limit the position or rotational displacement of the spacer.

[0063] In some embodiments, one or more contact features may be provided in or adjacent to the fiber optic array structure to assist in controlling the rotational orientation and / or position of the spacer. The contact features may take the form of dummy fibers as described above, but the contact features may be provided in another form. For example, the contact feature may be an object provided adjacent to the fiber optic array structure other than the fiber, and the object may extend out of the corresponding end groove and the surface in which the corresponding end groove is provided to contact the spacer. Alternatively, rather than placing the object in the end groove, the object may be attached (e.g., via fasteners, adhesives, etc.) to the surface of the first portion 302 (see Figure 3A )、the second portion 304 (see Figure 3A ) etc., such that the object helps to maintain contact with the spacer.

[0064] As another alternative, the contact feature may be provided integrally with one of the first portion 302 (see Figure 3A )、the second portion 304 (see Figure 3A ) etc., and the contact feature may extend outward from the corresponding surface to contact the spacer to assist in controlling the rotational orientation and / or position of the spacer (see, for example, Figure 4C and 4D ). For example, the contact feature may be integral with one of the first portion of the fiber optic array structure or the second portion of the fiber optic array structure. In some embodiments, the fiber optic array structure may be configured such that the first surface of the first portion or the second surface of the second portion contacts the spacer, and the first surface or the second surface may be considered a contact feature.

[0065] Additionally, in cases where some fibers in the fiber optic array are more sensitive to errors than other fibers, the sensitive fibers may be disposed in more central grooves of a set of grooves, while the less sensitive fibers may be disposed in grooves closer to the end grooves. For example, in cases where only a portion of the fibers in the fiber optic array are polarization maintaining fibers or multi-core fibers, these polarization maintaining fibers or multi-core fibers may be disposed in more central grooves, while the less sensitive fibers may be disposed in grooves closer to the end grooves. Since it is often important to maintain the proper rotational orientation of polarization maintaining fibers and multi-core fibers, placing these fibers in a central location can reduce the likelihood of improper rotational orientation of these fibers. In cases where the less sensitive fibers are disposed in the end grooves, these less sensitive fibers may constitute the contact feature.

[0066] Referring to Figure 7 , and to expand on some of the concepts detailed herein, if uncontrolled, the spacer may shift to an improper position. For example, the spacer 724A may typically be parallel to Figure 7extends in the length direction of the Y-axis. Ideally, the spacer 724A maintains this orientation and position during use, but certain forces acting on the spacer 724A may cause this orientation and position to change. For example, in the case where other optical fibers or contact features contact the spacer 724A above and below the spacer 724A, this may cause the spacer 724A to shift upward or downward at the ends of the spacer 724A, and may include rotation about the Z-axis at the ends. In addition, due to improper positioning of the optical fibers in the grooves, due to defects in manufacturing, and due to dimensional deviations caused by manufacturing tolerances, improper positioning may occur in the spacer 724A. Such improper positioning may cause undesirable changes in the positioning of the spacer 724A with respect to the X-direction, Y-direction, or Z-direction, and the improper positioning may cause undesirable changes in the rotational orientation of the spacer 724A about the X-axis, Y-axis, or Z-axis.

[0067] While various embodiments of a system or an optical fiber array structure have been described above, example methods of manufacturing such a system or an optical fiber array structure are shown in Figure 8 FIG. For example, at operation 802, an optical fiber array structure is provided. The optical fiber array structure may include a first portion and a second portion. The first portion may have a first surface in which a first set of grooves is defined, and the second portion may have a second surface in which a second set of grooves is defined. The second set of grooves may include a first end groove, a second end groove, and one or more additional grooves between the first end groove and the second end groove. At operation 804, a first optical fiber array and a second optical fiber array are provided. At operation 806, a spacer is provided. In addition, at operation 808, a first dummy optical fiber is provided. Alternatively, in some embodiments, a contact feature other than a dummy optical fiber may be provided, and the contact feature may be used in place of the dummy optical fiber.

[0068] At operation 810, each optical fiber in the first optical fiber array and the second optical fiber array is positioned in a groove. Each optical fiber in the first optical fiber array may be received in a groove in the first set of grooves. In addition, each optical fiber in the second optical fiber array may be received in a groove in the second set of grooves.

[0069] At operation 812, the spacer is positioned between the first optical fiber array and the second optical fiber array. At operation 814, the dummy optical fiber is positioned in the end groove. The dummy optical fiber may be positioned in the first end groove or the second end groove of the second set of grooves. The dummy optical fiber may help maintain the rotational orientation or position of the spacer relative to at least the first optical fiber array.

[0070] At operation 816, a first portion and a second portion of the fiber optic array structure are positioned relative to each other. The first portion of the fiber optic array structure may be positioned adjacent to the second portion of the fiber optic array structure such that a first surface of the first portion faces a second surface of the second portion and such that a first set of grooves extends parallel to a second set of grooves.

[0071] Although various operations are shown and described herein in a particular order, the order of the operations may be varied in other embodiments. For example, operation 804 may be performed before operation 802, operation 814 may be performed before operation 812, and so on. Alternatively, operation 802 and operation 804 may be performed simultaneously. Additionally, although various operations are shown and described herein, certain operations may be omitted in some embodiments and additional operations may be performed in some embodiments. Figure 8 Figure 8

[0072] Conclusion

[0073] Those skilled in the art who have benefited from the teachings presented in the foregoing description and the associated drawings will think of many modifications and other embodiments of the invention described herein. Accordingly, it is to be understood that the embodiments 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. In addition, 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 understood that different combinations of elements and / or functions may be provided by alternative embodiments without departing from the scope of the invention. In this regard, for example, combinations of elements and / or functions different from those explicitly described above are also considered to be within the scope of the invention. Accordingly, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. A system for improving fiber optic positioning, the system comprising: An optical fiber array structure, comprising: A first portion having a first surface in which a first set of grooves is defined; and A second portion having a second surface in which a second set of grooves is defined, wherein the second set of grooves includes a first end groove, a second end groove, and one or more additional grooves between the first end groove and the second end groove; A first optical fiber array, wherein each optical fiber in the first optical fiber array is located in a groove in the first set of grooves; A second optical fiber array, wherein each optical fiber in the second optical fiber array is located in a groove in the second set of grooves; A first spacer; and A first dummy optical fiber, Wherein the first portion of the optical fiber array structure is configured to be placed adjacent to the second portion of the optical fiber array structure such that the first surface of the first portion faces the second surface of the second portion, and such that the first set of grooves extends parallel to the second set of grooves, wherein the first spacer is disposed between the first optical fiber array and the second optical fiber array, wherein the first dummy optical fiber is disposed in one of the first end groove or the second end groove, and wherein the first dummy optical fiber is configured to assist in maintaining at least one of the rotational orientation or position of the first spacer relative to at least the first optical fiber array.

2. The system according to claim 1, wherein the first dummy optical fiber is configured to contact the first spacer when assembling the system.

3. The system according to claim 1, wherein the first spacer is configured to contact each of the optical fibers in the first optical fiber array and the second optical fiber array when the first optical fiber array is received in the first set of grooves and when the second optical fiber array is received in the second set of grooves.

4. The system according to any one of claims 1 to 3, wherein the first dummy optical fiber is configured to assist in maintaining at least one of the rotational orientation or position of at least one optical fiber in the first optical fiber array or the second optical fiber array.

5. The system according to any one of claims 1 to 3, wherein the first dummy optical fiber is configured to contact the first spacer to assist in maintaining at least one of the rotational orientation or position of the first spacer, and wherein the contact between the first dummy optical fiber and the first spacer causes the first spacer to contact an optical fiber in the first optical fiber array or the second optical fiber array such that the optical fiber is maintained in at least one of a proper rotational orientation or a proper position within the groove in the first set of grooves or the second set of grooves.

6. The system according to claim 5, wherein the first dummy optical fiber is configured to assist in controlling the orientation of the optical fibers in the first optical fiber array or the second optical fiber array.

7. The system according to claim 6, wherein the optical fibers within the first optical fiber array or the second optical fiber array are polarization maintaining optical fibers or multi-core optical fibers.

8. The system according to any one of claims 1 to 3, further comprising: a second dummy optical fiber, wherein the first dummy optical fiber is disposed in the first end groove, and wherein the second dummy optical fiber is disposed in the second end groove.

9. The system according to any one of claims 1 to 3, wherein the first optical fiber array and the second optical fiber array extend in a first direction, wherein the first spacer extends in a second direction, and wherein the second direction is perpendicular to the first direction.

10. The system according to claim 1, wherein each groove in the first set of grooves and the second set of grooves extends in a length direction, wherein the first set of grooves is aligned in a transverse direction perpendicular to the length direction, wherein the second set of grooves is aligned in the transverse direction, and wherein the first portion and the second portion are positioned relative to each other such that the first set of grooves and the second set of grooves are offset from each other in the transverse direction.

11. The system according to claim 1, further comprising one or more additional spacers, wherein the first spacer and the one or more additional spacers are disposed between the first optical fiber array and the second optical fiber array, and wherein the first dummy optical fiber is configured to assist in controlling at least one of the rotational orientation or the position of the first spacer and the one or more additional spacers.

12. The system according to any one of claims 1 to 3, wherein the optical fibers in the first optical fiber array or the second optical fiber array are optical waveguides.

13. The system according to claim 1, wherein the second portion has an opposite surface opposite to the second surface, and wherein the optical fiber array structure further comprises: a third portion having a third surface in which a third set of grooves is defined; a third optical fiber array, wherein each optical fiber in the third optical fiber array is located in a groove in the third set of grooves; and a second spacer, wherein the second portion of the optical fiber array structure is configured to be located between the first portion and the third portion of the optical fiber array structure, wherein the second portion of the optical fiber array structure is configured to be placed adjacent to the third portion of the optical fiber array structure such that the opposite surface of the second portion faces the third surface of the third portion, and such that the second set of grooves extends parallel to the third set of grooves, wherein the second spacer is disposed between the second optical fiber array and the third optical fiber array, wherein the first dummy optical fiber is configured to assist in maintaining at least one of the rotational orientation or the position of the first spacer relative to at least the first optical fiber array, and wherein the first dummy optical fiber is configured to assist in maintaining at least one of the rotational orientation or the position of the second spacer relative to at least the third optical fiber array.

14. The system according to claim 13, wherein the second spacer comprises the second portion.

15. An optical fiber array unit for improving optical fiber positioning, the optical fiber array unit comprising: Optical fiber array structure, comprising: A first portion having a first surface in which a first set of grooves is defined, each groove in the first set of grooves being configured to receive an optical fiber in a first optical fiber array; and A second portion having a second surface in which a second set of grooves is defined, each groove in the second set of grooves being configured to receive an optical fiber in a second optical fiber array, wherein the second set of grooves includes a first end groove, a second end groove, and one or more additional grooves between the first end groove and the second end groove, wherein the first portion of the optical fiber array structure is configured to be placed adjacent to the second portion of the optical fiber array structure such that the first surface of the first portion faces the second surface of the second portion and such that the first set of grooves extends parallel to the second set of grooves, wherein the optical fiber array unit is configured to receive a spacer between the first optical fiber array and the second optical fiber array, wherein at least one of the first end groove or the second end groove is configured to receive a first dummy optical fiber, and wherein the first dummy optical fiber helps maintain at least one of the rotational orientation or position of the spacer relative to at least the first optical fiber array.

16. A method for manufacturing a system for improving optical fiber positioning, the method comprising: Providing an optical fiber array structure having a first portion and a second portion, wherein the first portion has a first surface in which a first set of grooves is defined, wherein the second portion has a second surface in which a second set of grooves is defined, wherein the second set of grooves includes a first end groove, a second end groove, and one or more additional grooves between the first end groove and the second end groove; Providing a first optical fiber array; Providing a second optical fiber array; Providing a spacer; Providing a first dummy optical fiber; Positioning each optical fiber in the first optical fiber array in a groove in the first set of grooves; Positioning each optical fiber in the second optical fiber array in a groove in the second set of grooves; Positioning the spacer between the first optical fiber array and the second optical fiber array; Positioning the first dummy optical fiber in one of the first end groove or the second end groove, wherein the first dummy optical fiber helps maintain at least one of the rotational orientation or position of the spacer relative to at least the first optical fiber array; And Positioning the first portion of the optical fiber array structure adjacent to the second portion of the optical fiber array structure such that the first surface of the first portion faces the second surface of the second portion and such that the first set of grooves extends parallel to the second set of grooves.

17. A system for improving optical fiber positioning, the system comprising: An optical fiber array structure, comprising: A first portion having a first surface in which a first set of grooves is defined; and A second portion having a second surface in which a second set of grooves is defined; A first fiber optic array, wherein each optical fiber in the first fiber optic array is located within a groove in the first set of grooves; A second fiber optic array, wherein each optical fiber in the second fiber optic array is located within a groove in the second set of grooves; A spacer; and A contact feature, wherein the first portion of the fiber optic array structure is configured to be placed adjacent to the second portion of the fiber optic array structure such that the first surface of the first portion faces the second surface of the second portion and such that the first set of grooves extends parallel to the second set of grooves, wherein the spacer is disposed between the first fiber optic array and the second fiber optic array, wherein the contact feature is disposed at the second surface of the second portion, adjacent to the second set of grooves, and wherein the contact feature is configured to assist in maintaining at least one of the rotational orientation or position of the spacer relative to at least the second fiber optic array.

18. The system of claim 17, wherein the contact feature is configured to contact the spacer when assembling the system.

19. The system of claim 17, wherein the spacer is configured to contact each of the optical fibers in the first fiber optic array and the second fiber optic array when the first fiber optic array is received in the first set of grooves and when the second fiber optic array is received in the second set of grooves.

20. The system of claim 17, wherein the contact feature is integral with the second portion of the fiber optic array structure, and wherein when the contact feature is integral with the second portion, the contact feature protrudes from the second surface of the second portion of the fiber optic array structure.

21. The system of claim 17, wherein the contact feature is an object not integral with the second portion of the fiber optic array structure, wherein the second set of grooves includes a first end groove, a second end groove, and one or more additional grooves between the first end groove and the second end groove, and wherein the contact feature is received in the first end groove or the second end groove and protrudes beyond the second surface of the second portion of the fiber optic array structure.

22. The system of any one of claims 17 to 21, wherein the contact feature is configured to assist in maintaining at least one of the rotational orientation or position of at least one optical fiber in the first fiber optic array or the second fiber optic array.

23. The system of any one of claims 17 to 21, wherein the contact feature is configured to contact the spacer to assist in maintaining at least one of the rotational orientation or the position of the spacer, and wherein the contact between the contact feature and the spacer causes the spacer to contact an optical fiber in the first fiber optic array or the second fiber optic array such that the optical fiber is maintained in at least one of a proper rotational orientation or a proper position within the groove in the first set of grooves or the second set of grooves.

24. The system according to claim 23, wherein the contact feature is configured to assist in controlling the orientation of the optical fibers in the first optical fiber array or the second optical fiber array.

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