Optical fiber array spacer, optical assembly including same, and method of manufacturing same

Abstract

Optical fiber array spacers, optical fiber assemblies, optical assemblies, and methods for manufacturing optical assemblies are disclosed. In one embodiment, a fiber optic assembly includes a fiber optic array spacer and a fiber optic ribbon having a fiber optic array. The fiber array spacer has a spacer fiber array, wherein individual spacer fibers of the spacer fiber array are bonded to each other and the diameter of the individual spacer fibers determines the height of the fiber array spacer. Each optical fiber of the array of optical fibers has a glass portion. The glass portion of each optical fiber is bonded to the fiber array spacer such that the longitudinal axis of each spacer fiber is transverse to the longitudinal axis of each fiber of the fiber ribbon.

Description

[0001] This application is a divisional application of the invention patent application titled "Optical Fiber Array Spacer, Optical Component Comprising the Optical Fiber Array Spacer, and Method of Manufacturing the Same" with the application number 202011062701.X, filed on September 30, 2020.

[0002] Priority Application

[0003] This application claims the benefit of priority to U.S. Provisional Application No. 62 / 908,187, filed on September 30, 2019, relies on the content of these applications, and incorporates the entire content thereof herein by reference. Technical Field

[0004] The present disclosure generally relates to optical components, and more particularly, to optical components comprising an optical fiber array spacer having a precise height provided by fibers of precise diameter. Background Art

[0005] The benefits of optical fibers include extremely wide bandwidth and low-noise operation. Due to these advantages, optical fibers are increasingly used in various applications, including but not limited to broadband voice, video, and data transmission. Outdoor optical fiber networks have become popular to support the demand for data consumption. Due to high-speed wireless communication networks and the Internet of Things, many communication devices and antennas need to be equipped with optical fiber connections in order to transmit data into the optical fiber infrastructure required for such communication networks.

[0006] Low-cost optical fiber array components are important components for connector and photonic integrated circuit interconnections. For example, in order to couple with low loss to a lens array on a separate substrate, a two-dimensional optical fiber array with precise spacing may be required. Two-dimensional optical fiber array interconnections can also be used in high-density interconnections with photonic chip grating couplers. Such an optical fiber array requires not only precise lateral spacing between adjacent optical fibers, but also precise vertical spacing between the optical fibers of adjacent rows of optical fibers. Precise height placement of optical components may also be required in other optical applications.

[0007] However, providing a substrate with precise thickness with such precise height tolerances is expensive and difficult to manufacture. For example, it may be difficult to precisely draw a glass plate with the desired thickness. Additionally, machining or etching the substrate to the desired thickness may be time-consuming and expensive. Summary of the Invention

[0008] Optical communication applications that transfer one or more optical signals between two optical coupling devices may require vertical and horizontal alignment between the optical coupling devices. As a non-limiting example, the first and second optical coupling devices may include one or more waveguides or cores of an optical fiber. The waveguides or cores may be disposed on a reference surface such that they are spaced apart by an exact vertical offset distance above or below the reference surface. In some applications, the vertical offset is set to an easily achievable target, such as being equal to the radius of the optical fiber (e.g., 62.5 μm). In other applications, such as when the vertical offset distance is greater than the radius of the optical fiber, a vertical spacer may be employed.

[0009] In embodiments of the present disclosure, an optical fiber array spacer with high geometric precision is manufactured and used to provide an exact vertical offset distance in optical communication applications. The embodiments utilize the high geometric precision inherent in modern optical fibers to manufacture precision spacers. Such optical fiber array spacers can be used in any optical communication application, such as optical coupling between two optical cable assemblies, optical coupling between an optical cable assembly and a photonic chip, optical coupling between two photonic chips, and any other application where an optical signal passes between one optical device and another.

[0010] In this regard, in one embodiment, an optical fiber assembly includes an optical fiber array spacer and an optical fiber ribbon having an optical fiber array. The optical fiber array spacer has a spacer optical fiber array, wherein the individual spacer optical fibers of the spacer optical fiber array are bonded together. Each optical fiber of the optical fiber array has a glass portion. The glass portion of each optical fiber is bonded to the optical fiber array spacer such that the longitudinal axes of the individual spacer optical fibers are transverse to the longitudinal axes of the individual optical fibers of the optical fiber array.

[0011] In another embodiment, an optical component includes an optical fiber array spacer and a photonic integrated circuit bonded to the optical fiber array spacer. The optical fiber array spacer includes a spacer optical fiber array, wherein the individual spacer optical fibers of the spacer optical fiber array are bonded to each other.

[0012] [[ID=

[12] ]]In another embodiment, an optical fiber array spacer includes a spacer optical fiber array, each individual spacer optical fiber including a first surface defining a first plane and a second surface defining a second plane parallel to the first plane. The optical fiber array spacer further includes an adhesive disposed between adjacent spacer optical fibers, the adhesive bonding the individual spacer optical fibers to each other, wherein the adhesive does not extend beyond the first plane and the second plane.

[0013] In another embodiment, a method of manufacturing an optical fiber component includes disposing an optical component onto an optical fiber array spacer including a spacer optical fiber array. The individual spacer optical fibers of the spacer optical fiber array are bonded to each other. The method further includes bonding the optical component to the optical fiber array spacer. Description of the Drawings

[0014] Figure 1A Shows a perspective view of an example multi-fiber optical cable and optical fiber according to one or more embodiments described and shown herein, the multi-fiber optical cable having a portion of the cable jacket stripped away, the optical fiber having a glass portion with some protective coating remaining;

[0015] Figure 1B Shows a perspective view of another example multi-fiber optical cable and optical fiber according to one or more embodiments described and shown herein, the multi-fiber optical cable having a portion of the cable jacket stripped away, the optical fiber having a glass portion with all protective coating removed from the optical fiber after the cable jacket;

[0016] Figure 1C Shows an end view of an example optical fiber according to one or more embodiments described and shown herein;

[0017] Figure 2A Shows a partially exploded perspective view of an example assembly workbench for manufacturing optical fiber array spacers and / or optical fiber components according to one or more embodiments described and shown herein;

[0018] Figure 2B Shows a perspective view of an assembly workbench according to one or more embodiments described and shown herein showing the direction of the applied force by Figure 2A as shown;

[0019] Figure 3A Shows a cross-sectional view of an assembly workbench according to one or more embodiments described and shown herein showing the applied force by Figure 2A and 2B as shown;

[0020] Figure 3B Shows a cross-sectional view of another example assembly workbench for manufacturing optical fiber array spacers and / or optical fiber components using laser welding according to one or more embodiments described and shown herein;

[0021] Figure 4A Shows an end view of an interdigital optical fiber array and two anti-sticking sheets according to one or more embodiments described and shown herein;

[0022] Figure 4B Shows an end view of an example interdigital optical fiber array with the anti-sticking sheet removed according to one or more embodiments described and shown herein;

[0023] Figure 4C Shows an end view of an example interdigital optical fiber array bonded to a support plate according to one or more embodiments described and shown herein;

[0024] Figure 5AShows an example first multi-fiber optical cable and an example second multi-fiber optical cable joined at an interdigitated glass portion in accordance with one or more embodiments described and shown herein;

[0025] Figure 5B Shows an example first multi-fiber optical cable having a first interdigitated fiber array and an example second multi-fiber optical cable having a second interdigitated fiber array in accordance with one or more embodiments described and shown herein;

[0026] Figure 5C Shows a first multi-fiber optical cable having a first interdigitated fiber array to be cut along a cutting line in accordance with one or more embodiments described and shown herein;

[0027] Figure 5D Shows in accordance with one or more embodiments described and shown herein from Figure 5C An example fiber array spacer cut from the first multi-fiber optical cable shown;

[0028] Figure 6A Shows a perspective view of a first multi-fiber optical cable and a second multi-fiber optical cable joined at an interdigitated glass portion to be cut along a plurality of cutting lines in accordance with one or more embodiments described and shown herein;

[0029] Figure 6B Shows in accordance with one or more embodiments described and shown herein from Figure 6A A perspective view of an example fiber array spacer cut from the interdigitated glass portion shown;

[0030] Figure 6C Shows an end view of an example fiber array spacer including an intermediate spacer sheet in accordance with one or more embodiments described and shown herein;

[0031] Figure 7A Shows a perspective view of an example process of manufacturing an optical fiber component having a fiber array spacer or a two-layer fiber array spacer using a first multi-fiber optical cable and a second multi-fiber optical cable in accordance with one or more embodiments described and shown herein;

[0032] Figure 7B Shows a perspective view of another step in an example process of manufacturing an optical fiber component having a fiber array spacer or a two-layer fiber array spacer in accordance with one or more embodiments described and shown herein;

[0033] Figure 7C Shows a perspective view of an example optical fiber component in which a second multi-fiber optical cable is removed, or another step in manufacturing a two-layer fiber array spacer, in accordance with one or more embodiments described and shown herein;

[0034] Figure 8AShows a perspective view of an exemplary two-layer fiber optic array spacer obtained by the process shown according to one or more embodiments described and shown herein; Figure 7A - 7C A perspective view of an exemplary two-layer fiber optic array spacer obtained by the process shown;

[0035] Figure 8B Shows a side view of an exemplary two-layer fiber optic array spacer according to one or more embodiments described and shown herein; Figure 8A A side view of an exemplary two-layer fiber optic array spacer;

[0036] Figure 9 Shows a cross-sectional view of an exemplary assembly workbench for bonding a first interdigitated fiber optic array to a second interdigitated fiber optic array according to one or more embodiments of the present disclosure described and shown herein;

[0037] Figure 10 Shows an end view of an exemplary fiber optic component according to one or more embodiments described and shown herein;

[0038] Figure 11 Shows a cross-sectional view of an exemplary assembly workbench for manufacturing a two-dimensional fiber optic array according to one or more embodiments described and shown herein;

[0039] Figure 12 Shows a cross-sectional view of an exemplary two-dimensional fiber optic array according to one or more embodiments described and shown herein;

[0040] Figure 13A Shows a cross-sectional view of another exemplary assembly workbench for manufacturing a two-dimensional fiber optic array according to one or more embodiments described and shown herein;

[0041] Figure 13B Shows a cross-sectional view of another exemplary assembly workbench for manufacturing a two-dimensional fiber optic array according to one or more embodiments described and shown herein;

[0042] Figure 13C Shows a cross-sectional view of another exemplary assembly workbench for manufacturing a two-dimensional fiber optic array according to one or more embodiments described and shown herein;

[0043] Figure 13D Shows a cross-sectional view of another exemplary assembly workbench for manufacturing a two-dimensional fiber optic array according to one or more embodiments described and shown herein;

[0044] Figure 13E Shows a cross-sectional view of another exemplary assembly workbench for manufacturing a two-dimensional fiber optic array according to one or more embodiments described and shown herein;

[0045] Figure 14A perspective view of an example optical connector for an optical cable assembly having a two - dimensional optical fiber array and an optical fiber array spacer, according to one or more embodiments described and shown herein; and

[0046] Figure 15 A perspective view of an example optical component including a photonic integrated circuit coupled to a two - layer optical fiber array spacer, according to one or more embodiments described and shown herein. DETAILED DESCRIPTION

[0047] Embodiments described herein relate to optical fiber array spacers that provide precise thickness for optical components, optical components that include optical fiber array spacers, and methods of manufacturing the same. The optical fiber array spacers described herein are made of optical fibers and utilize the precise diameter of the exposed glass optical fibers to achieve optical fiber array spacers of highly precise thickness. The precision of the thickness of the optical fiber array spacer is based on the tolerance of the diameter of the spacer optical fibers that make up the optical fiber array spacer. It is much easier to manufacture drawn glass optical fibers with precise diameters than to manufacture sheets with uniform precise thickness. Thus, the embodiments described herein enable the low - cost manufacture of two - dimensional optical fiber arrays and other optical components that may require precision along the Y - axis (i.e., the vertical direction).

[0048] Various embodiments of optical fiber array spacers, optical component optical parts, and methods of manufacturing that include spacer optical fibers are described in detail herein.

[0049] Now referring to Figure 1A , an example multi - fiber optical cable 60 (i.e., an optical fiber ribbon) for manufacturing an optical fiber array spacer for an optical fiber component is shown. The multi - fiber optical cable 60 includes an array of optical fibers 52 supported by a cable jacket 61. The front end of the cable jacket 61 is stripped away, thereby exposing the array of optical fibers 52. As a non - limiting example, the stripping process for removing the cable jacket 61 can be performed using a mechanical stripper that heats and softens the cable jacket 61 before removing it using a pair of serrated blades.

[0050] The protective coating 76 is stripped away at the front end of the array of optical fibers 52 to expose the glass portion 74. However, it should be understood that the embodiments are not limited to optical fibers 52 having an exposed cladding. For example, the glass portion 74 can be a core portion. The protective coating 76 can be removed using a mechanical process similar to that described above for the cable jacket 61, or it can be removed by a laser - based stripping process. Although Figure 1A shows a portion of the protective coating 76 present on the exposed optical fiber array, the embodiments are not limited thereto. For example, Figure 1B shows the multi - fiber optical cable 60 in which substantially all of the protective coating 76 has been removed from the exposed array of optical fibers 52.

[0051] Referring to Figure 1C, each optical fiber 52 includes a core 72, a cladding 74 surrounding the core, and a protective coating 76 surrounding the cladding. As described above, the protective coating is stripped to provide the glass portion 74. The core 72 has a core diameter DC, the cladding has a cladding diameter DCL, and the protective coating has a protective coating diameter DPL. Because the diameter of the optical fiber is precisely controlled, the glass portion (i.e., the cladding) has an exact diameter DCL, which is used to form an optical fiber array spacer with an exact height to precisely align the optical fibers of an optical connector or an optical component. An example optical fiber for the optical fiber 52 is Corning Optical fiber, which has a diameter of 125 μm. However, the embodiments are not limited thereto. As another example, the optical fiber may have a cladding diameter DCL (or core diameter DC) of 250 μm. The optical fibers can be selected based on their diameters and can also be custom manufactured to have a desired diameter within specified tolerances.

[0052] Now refer to Figure 2A , an example assembly workbench 111 for manufacturing an optical fiber array spacer is shown. As described in more detail below, the assembly workbench 111 is used to cross the optical fibers of two multi-fiber optical cables 60. As used herein, the terms "cross each other" or "interdigitated" mean that the first and second optical fibers of two multi-fiber optical cables 60 (e.g., A and B) are arranged in an alternating pattern A-B-A-B-A-B, etc.

[0053] The shown assembly workbench 111 includes a support plate 20 (i.e., a first support substrate), a first anti-sticking sheet 131A, a first pusher element 110A, a second pusher element 110B, a second anti-sticking sheet 131B, and a cover plate 120 (i.e., a second support substrate).

[0054] The support plate 20 supports all the elements of the assembly workbench 111 and serves as a support surface for the applied vertical extrusion forces V1 and V2 ( Figure 2B ). The support plate 20 has a precision flat surface 22 such that any deviation from the ideal plane that mates with the precision flat surface 22 is less than or equal to 0.1 μm. The surface flatness of the precision flat surface 22 should be precisely controlled to ensure the consistent height of the resulting optical fiber array spacer. The support plate 20 can be made of any suitable material. As a non-limiting example, the support plate 20 can be a fused-drawn glass substrate with a uniform thickness.

[0055] The first anti - sticking sheet 131A is disposed on the precision flat surface 22 of the support plate 20. The first anti - sticking sheet 131A (and the second anti - sticking sheet 131B) can be implemented as a thin polymer sheet of uniform thickness (e.g., polytetrafluoroethylene (PTFE), polyvinylidene chloride (PVDC), and low - density polyethylene (LDPE) sheets), or it can be a thin surface coating of controlled uniform thickness (e.g., PTFE or oil coating) applied to the precision flat surface 22 before the application of the adhesive. The first anti - sticking sheet 131A should be thin enough so that sufficient ultraviolet (UV) radiation can be transmitted to enable adhesive curing, which will be described in more detail below. Additionally, the first anti - sticking sheet described herein should be thin enough (e.g., less than or equal to 10 μm or less than or equal to 5 μm) such that deformation of the anti - sticking sheet during manufacturing does not cause errors in the vertical alignment of the spacer optical fibers. As described in more detail below. Furthermore, the anti - sticking sheet described herein should have an exact thickness such that the anti - sticking sheet does not cause errors in the vertical alignment of the spacer optical fibers. As a non - limiting example.

[0056] In a specific non - limiting example, the first anti - sticking sheet 131A and / or the second anti - sticking sheet 131B can be configured to be, for example, a fluorosilane coating applied to the precision flat surface 22 at least by an impregnation process. The fluorosilane coating produces a durable monolayer that does not bond to the UV - cured adhesive. Since the fluorosilane anti - sticking coating can be applied to any material with surface oxides, such as metals or certain ceramics, they are also useful for coating other fixed elements, such as the first pusher element 110A and the second pusher element 110B described below.

[0057] The first multi - fiber optical cable 60A and the second multi - fiber optical cable 60B are used to manufacture the fiber array spacer. The first multi - fiber optical cable 60A includes a first cable sheath 61A that has been stripped to expose an array of first optical fibers 52A, which have a first protective coating portion 76A and a first glass portion 74A (which can be an exposed cladding or core). It should be understood that embodiments may not use multi - fiber optical cables but instead use bare optical fibers without protective coatings or cable sheaths.

[0058] Similarly, the second multi - fiber optical cable 60B includes a second cable sheath 61B that has been stripped to expose an array of second optical fibers 52B, which have a second protective coating portion 76B and a second glass portion 74B (which can be an exposed cladding or core). The second multi - fiber optical cable 60B provides an additional fiber array.

[0059] The first glass portion 74A and the second glass portion 74B can be the exposed cladding or core. However, in some embodiments, the first glass portion 74A and the second glass portion 74B can be coated with a coating to increase durability or improve laser welding, as described in more detail below. A non-limiting example is a titanium coating. The coating should be thin enough and its thickness controlled such that the coating does not adversely affect the precise diameter of the drawn fiber, which enables precise spacing of the fiber spacer array.

[0060] The glass portions 74A, 74B of the first optical fiber 52A and the second optical fiber 52B are arranged opposite to each other and cross each other on the first anti-stick sheet 131A. Thus, the interdigital fiber array includes alternating first optical fibers 52A and second optical fibers 52B.

[0061] The cover plate 120 includes a precision flat surface 122 such that any deviation from the ideal plane that mates with the precision flat surface 22 is less than or equal to 0.1 μm. A non-limiting example material is fused-drawn glass. As described in more detail below, the cover plate 120 applies a vertically downward force on the interdigital glass portions 74A, 74B of the first optical fiber 52A and the second optical fiber 52B.

[0062] An adhesive 135, such as a UV curable adhesive, is disposed on the interdigital glass portions 74A, 74B of the first optical fiber 52A and the second optical fiber 52B. A second anti-stick sheet 131B is disposed on the glass portions 74A, 74B of the first optical fiber 52A and the second optical fiber 52B and the adhesive 135. The second anti-stick sheet 131B can be a polymer sheet or a coating (such as a fluorosilane coating) that is applied to the precision flat surface 122 of the cover plate 120, as described above with respect to the first anti-stick sheet 131A. Thus, the first anti-stick sheet 131A and the second anti-stick sheet 131B are respectively positioned between the interdigital glass portions 74A, 74B and the support plate 20 and the cover plate 120 to prevent the interdigital glass portions 74A, 74B from permanently bonding to the support plate 20 and the cover plate 120.

[0063] The first pusher element 110A and the second pusher element 110B apply a horizontal force that presses the finger-like glass portions 74A, 74B together from opposite sides. The first pusher element 110A and the second pusher element 110B should have a thickness less than the diameter of the glass portions 74A, 74B of the first optical fiber 52A and the second optical fiber 52B so that they can slide between the support plate 20 and the cover plate 120. Examples of the first pusher element 110A and the second pusher element 110B include, but are not limited to, solid plates of glass, metal, plastic, or ceramic. In another non-limiting example, the first pusher element 110A and the second pusher element 110B can be an optical fiber array, the diameter of the optical fiber being less than the diameter of the finger-like glass portions 74A, 74B. As described above, the first pusher element 110A and the second pusher element 110B can be coated with a fluorosilane anti-stick coating, which is advantageous for elements coated with PTFE because the PTFE-coated pusher elements will experience delamination during the removal of the pusher elements after the adhesive cures, which results in damage to the pusher elements, and residual PTFE material remains along the sides of the optical fiber array, where the residual PTFE material can interfere with the precise passive alignment with other components.

[0064] Reference Figure 2B , the finger-like glass portions 74A, 74B are pressed by the first pusher element 110A applying a first lateral force L1 and the second pusher element 110B applying an opposite second lateral force L2. The first lateral force L1 and the second lateral force L2 drive the finger-like glass portions 74A, 74B into contact with each other such that there is substantially no gap (as a non-limiting example, less than 0.1 μm) between adjacent glass portions of the first optical fiber 52A and the second optical fiber 52B. A first vertical force V1 is applied through the cover plate 120, and a second vertical force V2 is applied through the support plate 20. The first vertical force V1 and the second vertical force V2 establish the position of the finger-like glass portions 74A, 74B in the Y direction.

[0065] Figure 3A A cross-sectional view looking down the axis of the finger-like glass portions 74A, 74B is provided. As Figure 3B shown, the finger-like glass portions 74A, 74B are an array of alternating first optical fibers 52A and second optical fibers 52B. The finger-like glass portions 74A, 74B define a finger-like optical fiber array 75. The first pusher element 110A and the second pusher element 110B can push the first optical fiber 52A and the second optical fiber 52B such that there is substantially no gap between adjacent optical fibers. This is advantageous in applications where the resulting optical fiber array spacer provides a V-grooved surface on its top surface for placing optical fibers. For example, the center-to-center spacing between adjacent optical fibers can be determined by the diameter of the optical fibers, for example, 125 μm. In other embodiments, there is no requirement for the spacing between adjacent optical fibers.

[0066] In some embodiments, a laser bonding technique can be used to form a rigid mechanical bond between adjacent glass portions of an optical fiber. For example, a metallized optical fiber is fabricated to be a weld feedthrough port in a hermetically sealed photonics component (e.g., an erbium pump amplifier). Optical fiber metallization can involve depositing a thin layer (e.g., ) of an optically absorptive material (e.g., stainless steel, chromium). The additional metallization layer is thin enough so as not to change the fiber diameter by more than the target specification.

[0067] Now referring to Figure 3B , the assembly workbench 111' is modified to include a laser beam delivery system 10 positioned directly over the interdigitated optical fiber array 75. The laser can be, but is not limited to, a Nd:YAG laser having a wavelength of 1.06 μm and delivering a pulsed laser beam 12 with a pulsed power of 0.1 - 2.0 kW. The laser beam focus 13 (20 - 50 μm in diameter) can be moved up, down, left, and right such that the focus can be positioned at the bonding interface between adjacent optical fibers.

[0068] After an extrusion force is applied to the interdigitated optical fiber array 75, the laser beam focus 13 is used to bond each adjacent pair of optical fibers 52A, 52B in the interdigitated optical fiber array 75. The laser activates and heats the optical fibers 52A, 52B so that they come into contact with each other, causing the metal coatings on the adjacent optical fibers 52A, 52B to melt and flow together. After the laser heating terminates, the metal cools and solidifies, forming a metallized bond 137 that holds the optical fibers 52A, 52B together. The laser bond 137 is restricted to the contact area between adjacent optical fibers 52A, 52B such that the distance between the top and bottom surfaces of each optical fiber 52A, 52B is equal to the original fiber diameter.

[0069] The laser beam focus 13 can also be translated parallel to the optical fiber axis to provide a long metallized bond between adjacent optical fibers 52A, 52B, which can be mechanically stronger than a weld at a single point. If the interdigitated optical fiber array 75 can be easily removed from the support plate 20 and the cover plate 120 after laser welding, the first anti - sticking sheet 131A and the second anti - sticking sheet 131B shown in Figure 3B may not be required.

[0070] Depending on the optical properties of the cover plate 120 and the first anti - sticking sheet 131A (if used), it may be desirable to divide these components into two parts to provide an unobstructed optical path between the laser beam 12 and the interdigitated optical fiber array 75. Although these components are separate, they are still able to provide a vertical extrusion force in the vicinity of the laser welding area. This ensures that during laser welding, the interdigitated optical fiber arrays 75 are properly aligned with each other and with the top and bottom plates. The top plate can also be made of a piece of glass with a hole in the middle to ensure that its left and right bottom surfaces are coplanar.

[0071] Now refer to Figure 3A and 3B such that the elastic modulus of the first anti - sticking sheet 131A and the second anti - sticking sheet 131B can be low enough to allow the anti - sticking sheets to deform during the application of the first vertical force V1 and the second vertical force V2. The deformation of the anti - sticking sheets should be approximately uniform over the finger - like glass portions 74A, 74B to ensure that the compressed finger - like glass portions 74A, 74B remain parallel to the support plate 20 and the cover plate 120. The deformation of the anti - sticking sheets helps to ensure that there is substantially no adhesive residue on the top and bottom surfaces of the finger - like glass portions 74A, 74B, such that the distance between these surfaces is precisely determined by the diameter of the optical fiber.

[0072] The first pusher element 110A and the second pusher element 110B can be designed to be removed after the optical fiber array spacer is assembled. For example, if the pusher elements 110A, 110B are designed to extend only a small distance (e.g., 300 - 500 μm) between the support plate 20 and the cover plate 120, they can be removed after the adhesive cures. A non - sticky coating or other anti - sticking material can be used to prevent the adhesive from adhering to the pusher elements 110A, 110B.

[0073] In other embodiments, the first pusher element 110A and the second pusher element 110B can be designed to disconnect during a subsequent assembly step, such that the tips of the first pusher element 110A and the second pusher element 110B remain. The lengths of the first pusher element 110A and the second pusher element 110B can be extended to allow them to be used as handles to simplify the positioning of the optical fiber array spacer in subsequent assembly steps.

[0074] After the adhesive cures (which can be by UV curing and / or heat curing steps), the first multi - fiber optical cable 60A and the second multi - fiber optical cable 60B are removed from the assembly workbench 111. If the first anti - sticking sheet 131A and the second anti - sticking sheet 131B are implemented as discrete sheets or films (as opposed to coatings), the first anti - sticking sheet 131A and the second anti - sticking sheet 131B will initially remain on the finger - like glass portions 74A, 74B, as Figure 4A shown. After removing the first anti - sticking sheet 131A and the second anti - sticking sheet 131B, the assembly is as Figure 4B shown. Note that the first cable sheath 61A or the second cable sheath 61B is not shown in Figure 4A and 4B During assembly, the compression of the first anti - sticking sheet 131A and the second anti - sticking sheet 131B by the finger - like glass portions 74A, 74B produces a wavy top optical fiber surface T (i.e., the first surface) and a bottom optical fiber surface B (i.e., the second surface). As Figure 4BAs shown, the top fiber optic surface T defines a first plane P1, and the bottom fiber optic surface B defines a second plane P2 parallel to the first plane P1. The adhesive 135 does not extend beyond the first plane P1 and the second plane P2. As described below, this surface variation can reduce the impact of dust and debris during the stacking of the fiber optic array spacers.

[0075] The adhesive 135 for joining adjacent optical fibers can be a flexible low modulus adhesive that allows the resulting fiber optic array spacer to conform to the surface on which it is placed, such that the fiber optic array spacer is positioned in a manner that is precisely perpendicular to the mounting surface. A high modulus adhesive can also be used between adjacent optical fibers to produce a rigid fiber optic array spacer. This type of fiber optic array spacer may be desirable in applications where the fiber optic array spacer serves as a geometric reference surface for additional components that are joined to the fiber optic array spacer.

[0076] In some embodiments, the support plate 20 and / or the cover plate 120 are elements of the resulting fiber optic array spacer. Referring again to Figure 3A and 3B , the first anti-stick sheet 131A and / or the second anti-stick sheet 131B may not be provided. Thus, when the first anti-stick sheet 131A is not provided, the interdigitated fiber optic array 75 will be bonded to the support plate 20, and when the second anti-stick sheet 131B is not provided, the interdigitated fiber optic array 75 will be bonded to the cover plate 120.

[0077] The support plate 20 and / or the cover plate 120 can be manufactured with precise thicknesses. The glass support plate 20 with an extremely flat surface (e.g., deviation from an ideal plane of less than 0.1 μm) can be manufactured using the fused draw method. The support plate 20 can be made of other materials, such as a CTE-matched silicon substrate, a glass-ceramic material, or a ceramic material. The same process can produce a glass plate with parallel top and bottom surfaces and precise thickness control. In these embodiments, the entire fiber optic array and its support plate can be used as a precision spacer.

[0078] Figure 4C An embodiment is shown where the first anti-stick sheet 131A is not provided on the surface 22 of the support plate 20, such that the adhesive 135 bonds the interdigitated fiber optic array 75 to the support plate 20 during the interlacing process as described above and Figure 3A and 3B shown. This is a single-step process.

[0079] The interdigitated fiber optic array 75 bonded to the support plate 20 can also be manufactured through a two-step process. First, through Figure 3A , 3B and 4A's process as Figure 4BThe manufacturing of the interdigital fiber optic array 75 is shown. Next, a layer of adhesive is applied to the support plate 20, and then the interdigital fiber optic array 75 is bonded to the surface 22 of the support plate.

[0080] In each case, the lower support plate 20 can be a thin glass sheet or an optical fiber array spacer manufactured to be precisely flat (formed between flat plates such as a fused-drawn glass plate).

[0081] Figure 5A The first multi-fiber optical cable 60A and the second multi-fiber optical cable 60B joined at the interdigital glass portions 74A, 74B by the process using the above-described assembly workbench 111 are shown. Multiple optical fiber array spacers can be obtained from a single interdigital fiber optic array 75. As Figure 5A shown, for example but not limited to, by scribing and breaking bare optical fibers, diamond sawing, or laser splitting, the interdigital fiber optic array 75 is cut along the cutting line CL.

[0082] After cutting, the first interdigital fiber optic array 75A is attached to the first multi-fiber optical cable 60A, and the second interdigital fiber optic array 75B is attached to the second multi-fiber optical cable 60B, as Figure 5B shown. The first interdigital fiber optic array 75A includes a first glass portion 74A of the alternating first optical fibers 52A and spacer optical fibers 77, which are fiber ferrules cut from the second optical fibers 52B of the second multi-fiber optical cable 60B. A fiber ferrule is a short length of optical fiber that does not transmit optical signals. The second interdigital fiber optic array 75B includes a second glass portion 74B of the alternating second optical fibers 52B and spacer optical fibers 77, which are fiber ferrules cut from the first optical fibers 52A of the first multi-fiber optical cable 60A.

[0083] In some applications, it is desirable for the optical fiber array spacer to remain attached to the multi-fiber optical cable to simplify the handling and positioning of the optical fiber array spacer. In Figure 5B the illustrated embodiment, the first optical fiber array spacer 80A is defined by the first interdigital fiber optic array 75A, and the second optical fiber array spacer 80B is defined by the second interdigital fiber optic array 75B.

[0084] In other applications, a single optical fiber array spacer without an attached multi-fiber optical cable may be desired. Figure 5C The cutting line CL that can be used to completely separate the first optical fiber array spacer 80A from the first multi-fiber optical cable 60A is shown. Figure 5D The completely separated optical fiber array spacer 80 that can be used in an optical device such as an optical connector is shown.

[0085] Although Figure 5DAn optical fiber array spacer 80 is shown with substantially no gaps between adjacent spacer optical fibers 77, but the embodiments are not limited thereto. For example, gaps may exist between adjacent spacer optical fibers 77. An adhesive may be present within the gaps to fix the respective spacer optical fibers 77 to each other. Additionally, the spacer optical fibers 77 do not need to be parallel to each other.

[0086] In some embodiments, the optical fiber array spacer 80 further includes a precision support plate 20 as Figure 4C shown and described above.

[0087] Figure 6A Shows how to separate multiple optical fiber array spacers 80 from a single interdigitated optical fiber array 75 using multiple cutting lines CL. Figure 6B Shows three separated optical fiber array spacers 80 from Figure 6A the single interdigitated optical fiber array 75 shown.

[0088] Note that the optical fiber array spacer can be fabricated with as few as two precisely-diameter optical fibers. In embodiments having only two optical fibers, the optical fiber array spacer will be most stable if it is fabricated with two optical fibers that are spaced apart as far as practicable.

[0089] Now referring to Figure 6C , in some embodiments, an optical fiber array spacer 80-1 may include at least two spacer optical fibers 77 that are spaced apart by an intermediate spacer sheet 78 having a height H that is less than the diameter of the spacer optical fibers 77 (e.g., the diameter DCL of the cladding). The H of having the intermediate spacer sheet 78 S ensures that only the upper and lower surfaces of at least two spacer optical fibers 7 are used to define the thickness of the optical fiber array spacer 80-1. S The optical fiber array spacer 80-1 of Figure 6C can be fabricated in a manner similar to that shown and described above, except that the internal spacer optical fiber is replaced by at least two outer spacer optical fibers 77. The intermediate spacer sheet 78 may be bonded to the spacer optical fibers 77 by an adhesive 135, as Figure 2A - 4B shown, or it may be bonded to the spacer optical fibers 77 by laser welding. The intermediate spacer sheet 78 may be made of any suitable material. For example, the intermediate spacer may be a flexible elastomer or a rigid material such as glass. Figure 6C shown, or it may be bonded to the spacer optical fibers 77 by laser welding. The intermediate spacer sheet 78 may be made of any suitable material. For example, the intermediate spacer may be a flexible elastomer or a rigid material such as glass.

[0090] The optical fiber array spacer may also be fabricated with a one-piece support sheet (not shown) that stiffens the optical fiber array. For example, referring to Figure 3A and 3B, a support sheet can be provided between the finger-like fiber optic array 75 and the support plate 20. An adhesive bonds the finger-like fiber optic array 75 to the support sheet. The support sheet can be made of any material that provides a flat surface, such as polished glass, ceramic, or metallic material. For example, a glass support sheet with an extremely flat surface (e.g., deviation from an ideal plane of less than 0.1 μm) can be fabricated using the fused draw method. In some embodiments, the support sheet can be rigid. However, the support sheet can also be thin enough to be flexible. If the support sheet is made of metal, metallized optical fibers can be laser welded to the support sheet by the laser welding process described above.

[0091] Now referring to Figure 7A , the support sheet can be replaced by a second fiber optic array spacer located beneath the first fiber optic array spacer, thereby creating a two-layer fiber optic array spacer including fiber optic ferrules. In Figure 7A , the first multi-fiber optical cable 60A is arranged transversely to the second multi-fiber optical cable 60B. Adhesive 135 is applied to the top surface of the second finger-like fiber optic array 75B (i.e., the second fiber optic array spacer 80B remains attached to the second multi-fiber optical cable 60B). Referring to Figure 7B , the second finger-like fiber optic array 75B and the first finger-like fiber optic array 75A (i.e., the second fiber optic array spacer 80A remains attached to the first multi-fiber optical cable 60A) are brought into contact with each other by a vertical force. Then the adhesive 135 is cured to fix the first fiber optic array spacer 80A to the second fiber optic array spacer 80B, thereby forming a two-layer fiber optic array spacer 80'.

[0092] Although the spacer fibers 77 of the first fiber optic array spacer 80A are shown as being orthogonal to the spacer fibers 77 of the second fiber optic array spacer 80B, the embodiments are not limited thereto. The fiber optic ferrules of the first fiber optic array spacer 80A and the second fiber optic array spacer 80B should be transverse to each other, but an orthogonal arrangement is not necessary.

[0093] Before or after the adhesive bonding, excess fiber optic array material can be removed from the first fiber optic array spacer 80A and / or the second fiber optic array spacer 80B. Figure 7C A perspective view of the two-layer fiber optic array spacer 80' is shown after cutting off and removing the remaining portion of the second multi-fiber optical cable 60B from the second fiber optic array spacer 80B. The remaining first optical fibers 52A and the first cable jacket 61A can be used as handles to support and align the two-layer fiber optic array spacer 80' during subsequent alignment and assembly operations.

[0094] Figure 8A A perspective view of an example is shown in which the two-layer fiber optic array spacer 80″ is separated from both the first multi-fiber optical cable 60A and the second multi-fiber optical cable 60B. Figure 8B Shown is Figure 8ACross-sectional view of the two-layer fiber optic array spacer 80" shown. The first layer is defined by a first fiber optic array spacer 80A having an array of spacer fibers 77, and the second layer is defined by a second fiber optic array spacer 80B having an array of additional spacer fibers 77.

[0095] Now referring to Figure 9 , a two-layer fiber optic array spacer with vertical fiber optic array spacers can also be assembled by a laser bonding process. Figure 9 A cross-sectional view of an assembly workbench 111' is shown, where a laser beam delivery system 10 is used for laser welding metallized optical fibers. Laser bonding 137 bonds adjacent optical fibers in the same interdigitated fiber optic array. Additionally, laser bonding 137 bonds the first interdigitated fiber optic array 75A to the second interdigitated fiber optic array 75B.

[0096] An advantage of the fiber optic array spacers described herein is that the optical fibers precisely set the thickness of the fiber optic array spacers. Thus, if a precision spacer of a given thickness is required in an optical component (e.g., an optical connector) or any type of component not limited to optical components, the precision spacer can be fabricated by drawing an optical fiber of the desired diameter. This is much easier than, for example, using a fused draw method to draw a glass sheet to a target thickness or polishing a substrate to a target thickness. As an example, a series of optical fibers can be drawn in different standard diameters such that by mixing and matching the upper and lower fiber optic array spacer thicknesses, the desired combined thickness can meet the target thickness.

[0097] Another advantage is that the optical fibers provide contact lines on both the top and bottom surfaces, which are more resistant to debris contamination that would otherwise cause thickness errors during stacking. The cavities formed between the optical fibers during the staggered bonding provide locations for debris to flow through during surface mating. At the same time, the limited total surface area during contact between the optical fibers and other fiber optic arrays or flats creates a high pressure that tends to compress the debris to reduce its error effect on the stacking height.

[0098] Referring again to Figure 7C , the fiber optic component 100 shown can be used as a one-dimensional fiber optic array, where the second fiber optic array spacer 80B serves as a spacer element in the final optical package, and the first interdigitated fiber optic array 75A is used to transmit and / or receive optical signals. Thus, the first multi-fiber optical cable 60A is an optical fiber cable that can be accommodated in a connector body (see Figure 14, which will be described in more detail below). The optical fibers of the optical fiber assembly 100 shown include an array of interdigital first glass portions 74A (from the first optical fiber 52A) and lateral spacer optical fibers 79 (cut from the second multi-fiber optical cable 60B as described above with respect to the spacer optical fiber 77). In this embodiment, the first optical fibers 52A are signal optical fibers because they propagate optical signals for optical communication. The lateral spacer optical fibers 79 are optical fiber ferrules similar to the spacer optical fibers 77 and are thus dummy optical fibers because they are not used for optical communication.

[0099] Preformed optical fiber assemblies (including optical fiber array spacers and arrays of interdigital glass portions of optical fibers and spacer optical fibers) can be stacked to achieve a two-dimensional optical fiber array. In Figure 10 one method shown, an optical fiber assembly 100 as shown in Figure 7C is used, in which a one-dimensional array of signal optical fibers 52A has an exact spacing provided by the lateral spacer optical fibers 79 and is supported by the optical fiber array spacer 80 of the spacer optical fibers 77. The optical fiber array spacer 80 is laterally displaced relative to the interdigital array of signal optical fibers 52A and the lateral spacer optical fibers such that it undercuts the interdigital array by a distance D1, where 0 μm ≤ D1 ≤ D / 2, and where D is the optical fiber diameter. Opposite ends of the optical fiber array spacer 80 extend beyond the interdigital array by a distance D2, where, for example, 0.5 mm ≤ D1 ≤ 2 mm. These offsets facilitate the assembly of the two-dimensional optical fiber array as described below.

[0100] Now referring to Figure 11 , an assembly workbench 111A can be constructed by mounting a precision vertical alignment block 140 on the precision flat surface 22 of the support plate 20. The precision flat surface 22 of the support plate 20 serves as a bottom-side alignment surface. The precision flat surface 141 of the vertical alignment block 140 serves as a left-side alignment surface. The precision vertical alignment block 140 and the support plate 20 together provide an exact right-angle corner, which enables the first interdigital optical fiber array 75 and the second interdigital optical fiber array 75' to be aligned left and right. In some embodiments, the vertical alignment block 140 and the support plate 20 serving as a horizontal alignment block are integrated into a single right-angle component.

[0101] In the illustrated embodiment, a first optical fiber assembly 100 including a first optical fiber array spacer 80 is disposed on an anti-stick sheet 131 on a precision flat surface 22 of a support plate 20. The first finger-like optical fiber array 75 of the first optical fiber assembly 100 is fixed to the first optical fiber array spacer 80 as described above. A second optical fiber assembly 100' including a second optical fiber array spacer 80' fixed to a second finger-like optical fiber array 75' is stacked on the first optical fiber assembly 100 such that the second optical fiber array spacer 80' is positioned on the first finger-like optical fiber array 75. An additional top precision spacer sheet 142 (e.g., precision flat fused glass) is applied on the second finger-like optical fiber array 75', and a cover plate 120 is positioned on the top precision spacer sheet 142. In some embodiments, the top precision anti-stick sheet 142 is not provided. Alternatively, an anti-stick sheet may be provided on the bottom surface 143 of the top precision spacer sheet 142 such that the precision support sheet is not a part of the resulting two-dimensional optical fiber array.

[0102] The downward force V1 applied using the cover plate 120 forces the first optical fiber assembly 100 and the second optical fiber assembly 100' into contact with each other. An adhesive 135 is applied between the first optical fiber assembly 100 and the second optical fiber assembly 100'. The adhesive 135 is prevented from adhering to the vertical alignment block 140 and the support plate 20 by using a first anti-stick sheet 133 and a second anti-stick sheet 131, respectively. As described above, the first anti-stick sheet 133 and the second anti-stick sheet 131 may be configured as separate sheets, or coatings, such as fluorosilane coatings.

[0103] Using a first pusher element 110A and a second pusher element 110B that respectively contact the outermost optical fibers in the first finger-like optical fiber array 75 and the second finger-like optical fiber array 75', the first optical fiber assembly 100 and the second optical fiber assembly 100' are laterally pushed into the precision flat surface 141 of the vertical alignment block 140. The first pusher element 110A and the second pusher element 110B are guided by portions of the optical fiber array spacers 80, 80' that extend a distance D2 to the right to contact the outermost optical fibers (see Figure 10 ). The first pusher element 110A and the second pusher element 110B force the outermost optical fibers in each finger-like optical fiber array to be pushed into contact with the anti-stick sheet 133 attached to the vertical alignment block 140. Due to the precise control of the thickness of the anti-stick sheet 133, the optical fibers in the first finger-like optical fiber array 75 and the second finger-like optical fiber array 75' become vertically aligned with each other (i.e., each core is exactly above the core below it). This causes all the optical fibers in the two-dimensional optical fiber array to be precisely positioned relative to each other in a grid. In this example, the two-dimensional horizontal optical fiber array pitch is equal to twice the fiber diameter, while the two-dimensional vertical optical fiber array pitch is equal to the sum of the fiber diameter and the diameter of the spacer optical fiber 77.

[0104] After the adhesive is UV-exposed and cured, the two-dimensional fiber optic array 210 is removed from the assembly workbench 112, as Figure 12 shown. The two-dimensional fiber optic array 210 can be disposed, for example, in an optical connector. The first interdigitated fiber optic array 75 includes alternating laterally-spaced spacer fibers 79 and signal fibers 52A, and is supported by a first fiber optic array spacer 80. The second interdigitated fiber optic array 75' includes alternating laterally-spaced spacer fibers 79' and signal fibers 52A', and is supported by a second fiber optic array spacer 80'.

[0105] Figure 13A Another assembly workbench 111B for assembling the two-dimensional fiber optic array is shown, which is similar to Figure 11 the assembly workbench 111A shown. In this embodiment, the extension lengths of the spacer fibers 77, 77' of the first fiber optic array spacer 80 and the second fiber optic array spacer 80' are respectively used to simplify the process of forcing the outermost fibers of the first interdigitated fiber optic array 75 and the second interdigitated fiber optic array 75' (i.e., the leftmost fiber in FIG. 13) against the precision flat surface 141 of the vertical alignment block 140. A large pusher element 110C (e.g., a pusher block) contacts the spacer fibers 77, 77' and applies a lateral force L. The pusher element 110C can have a thickness closely matching the total thickness of the stack of the first fiber optic assembly 100 and the second fiber optic assembly 100'. In the embodiment shown, an elastic pad 138 is provided on the end of the pusher element 110C such that the force is transmitted to each of the spacer fibers 77, 77' even if the spacer fibers 77, 77' have different lengths.

[0106] Figure 13B Another assembly workbench 111C for assembling the two-dimensional fiber optic array is shown, which is similar to Figure 13A the assembly workbench 111B shown. In this example, the extension lengths of the spacer fibers 77, 77' of the first and second fiber optic array spacers 80, 80' are respectively such that D2 (see Figure 10 ) is about 3 - 5 mm. This additional length allows the spacer fibers 77, 77' to bend when a force is applied to them via pusher elements 110D, such as the first pusher element 110A and the second pusher element 110C (see Figure 3A ), which are configured to squeeze the first fiber 52A and the second fiber 52B to form the pusher fibers of the interdigitated array. An example pusher element 110D is constructed as a block having a pocket 115 with a shoulder 117, which prevents the deflected spacer fibers 77, 77' from slipping off the end of the pusher element 110D. The elastic pad 138 may or may not be used in this embodiment. After alignment and adhesive curing, the excess lengths of the spacer fibers 77, 77' can be removed via a cutting or grinding operation.

[0107] Now refer to Figure 13C , another assembly workbench 111D for assembling a two-dimensional optical fiber array is similar to the Figure 13A and 13B shown assembly workbenches 111B and 111C. In this example, the lengths of the spacer optical fibers 77, 77' are reduced such that D2 (see Figure 10 ) is approximately 0 μm. Thus, the ends of the spacer optical fibers 77, 77' are aligned with the outermost optical fibers (i.e., the rightmost optical fibers) in each of the first finger-like optical fiber array 75 and the second finger-like optical fiber array 75'. A pusher element 110E having an elastic pad 138 at its end is used to simultaneously push the first optical fiber assembly 100 and the second optical fiber assembly 100' into the anti-stick sheet 133 on the precision flat surface 141 of the vertical alignment block 140.

[0108] Refer to Figure 13D , the two-dimensional optical fiber array 200 can be fabricated using only one optical fiber array spacer 80, which is disposed between the first finger-like optical fiber array 75 and the second finger-like optical fiber array 75'. In this instance, the first finger-like optical fiber array 75 is disposed on a first anti-stick sheet 131 on the precision flat surface 22 of the support plate 20 of the exemplary assembly workbench 111E. Next, the support finger-like optical fiber array 75″ is disposed on the first finger-like optical fiber array 75 such that its longitudinal axis is transverse (e.g., perpendicular) to the longitudinal axis of the first finger-like optical fiber array 75. As used herein, "perpendicular" means within ±5 degrees of 90 degrees. When the glass portion 74 is cut and the coating portion 76 is separated from the assembly, the support finger-like optical fiber array 75″ will become the spacer optical fiber 77. The second finger-like optical fiber array 75' is disposed on the support finger-like optical fiber array 75″. A vertical force V is applied through the cover plate 120 to establish the positions of the first finger-like optical fiber array 75 and the second finger-like optical fiber array 75' in the Y direction. First pusher elements 110A and second finger-like optical fiber arrays 110B apply transverse forces L1, L2 to the first finger-like optical fiber array 75 and the second finger-like optical fiber array 75', respectively, to force the outermost optical fibers (e.g., the leftmost optical fibers) of the first finger-like optical fiber array 75 and the second finger-like optical fiber array 75' to contact the anti-stick sheet 133 on the precision flat surface of the vertical alignment block 140. After the adhesive cures, the optical fiber assemblies are removed from the vertical alignment block 140, the support plate 20, and the cover plate 120. The excess optical fibers of the support finger-like optical fiber array 75″ are removed by cutting, thereby forming the optical fiber array spacer 80 disposed between the first finger-like optical fiber array 75 and the second finger-like optical fiber array 75'.

[0109] Figure 13EShows another example assembly workbench 111F, which can be used to manufacture two-dimensional fiber optic arrays in various configurations. In particular, the vertical alignment block 140 is mounted on a precision rotary stage (represented by array A) that can rotate relative to the fixed support plate 20. In the illustrated embodiment, as Figure 13D The two-dimensional fiber optic array 200 shown is disposed on a bottom precision spacer sheet 144 (e.g., a precision fused-drawn glass sheet). The bottom precision spacer sheet 144 provides a clearance C1 for the vertical alignment block 140 to rotate. In the case where the bottom precision spacer sheet 144 is not desired in the final product, an anti-stick sheet can be provided on the top surface of the bottom precision spacer sheet 144.

[0110] In Figure 13E the example of, a top precision spacer sheet 142 is disposed on the second interdigital fiber optic array 75'. The top precision spacer sheet 142 provides a clearance C2 for the rotation of the vertical alignment block. In the case where the top precision spacer sheet 142 is not desired in the final product, an anti-stick sheet can be provided on the bottom surface of the top precision spacer sheet 142.

[0111] By placing a right-angle gauge on the support plate 20 and adjusting the vertical alignment block 140' until it is parallel to the vertical side surface of the right-angle gauge, an exact right angle can be established between the vertical alignment block 140' and the support plate 20. Alternatively, the vertical alignment block 140' can be aligned by the peak optical power of the retroreflected light from a collimator that generates an exact beam extending parallel to the support plate 20. Thus, an optical signal parallel to the precision flat surface 22 of the support plate 20 can be emitted such that it is reflected by the precision flat surface 141 of the vertical alignment block 140'. The reflected optical signal is detected by a detector, and the vertical alignment block 140' is rotated until peak power is received at the detector.

[0112] The angular adjustment of the vertical alignment block 140' enables different configurations of the two-dimensional fiber optic array. For example, a two-dimensional fiber optic array can be manufactured in which the fiber cores are not exactly positioned on top of each other, but are laterally offset by an exact offset distance in the X direction. FIG. 13 shows an offset distance OD of zero. However, rotation of the vertical alignment block 140' results in an offset distance OD between the cores of the stacked fibers.

[0113] Any of the fiber optic array spacers and fiber optic arrays described herein can be implemented in any optical component. The exact diameter of the fiber used to manufacture the fiber optic spacer enables a low-cost method of achieving the position of the signal fiber (or waveguide) along the X-axis.

[0114] Now refer to Figure 14, showing an optical component in the form of an optical fiber connector 301 for an optical cable assembly 300. An exemplary optical fiber connector 301 has a connector body 302 having a mating surface 303 that can mate with a socket, a waveguide assembly (e.g., a waveguide assembly of a photonic integrated circuit (PIC)), or any other optical component. The connector body 302 can be of any shape and include any retaining features to facilitate physical mating.

[0115] The mating surface 303 has an opening 304 that exposes the end face of the optical fiber assembly 100 disposed within the connector body 302. The optical fiber assembly 100 includes a one-dimensional interdigitated optical fiber array 75 that includes alternating spacer optical fibers 79 and signal optical fibers 52 of a multi-fiber ribbon optical cable 60. The interdigitated optical fiber array 75 is supported on two layers of precision optical fiber array spacers 80", which precisely establish the height of the end faces of the signal optical fibers 52 relative to the bottom surface 305 of the opening by the precise diameter of the spacer optical fibers 77.

[0116] It should be understood that multi-dimensional optical fiber arrays can be utilized and any number of signal optical fibers can be provided. Any of the optical fiber array spacers and optical fiber arrays described herein can be disposed within the connector.

[0117] The optical fiber array spacers described herein can also be used in photonic applications. Figure 15 An exemplary photonic component 400 is shown that includes a PIC 401 mounted on two layers of optical fiber array spacers 80". The PIC 401 can be bonded to the two layers of optical fiber array spacers 80″, for example, by an adhesive or laser welding. The PIC 401 has a plurality of integrated waveguides 402 that are optically coupled to one or more active optical components 403 (e.g., optical transmitters and / or optical receivers) and terminate at an optical coupling surface 404.

[0118] The two layers of optical fiber array spacers 80" include a first optical fiber array spacer 80A and a second optical fiber array spacer 80B. The height h of the two layers of optical fiber array spacers 80" is equal to the diameter of the spacer optical fibers of the first optical fiber array spacer 80A plus the diameter of the spacer optical fibers of the second optical fiber array spacer 80B. The two layers of optical fiber array spacers 80" precisely set the position of the end faces of the waveguides 402 along the Y-axis, enabling precise coupling with an optical component that mates with the PIC 401 at the optical coupling surface 404.

[0119] It should be understood that the embodiments described herein can be implemented in any optical component and are not limited to Figure 14 the optical fiber connector 301 and Figure 15 the photonic component.

[0120] It is obvious to those skilled in the art that various modifications and variations can be made without departing from the spirit or scope of the present disclosure. Since those skilled in the art can conceive of modifications, combinations, sub-combinations, and variations of the disclosed embodiments that incorporate the spirit and substance of the present disclosure, the present disclosure should be construed to include all such modifications and equivalents within the scope of the appended claims and their equivalents.

Claims

1. An optical fiber component (100, 300, 400), comprising: A first optical fiber array spacer (80, 80A, 80B), comprising: A spacer optical fiber array, wherein each spacer optical fiber (77) of the spacer optical fiber array is combined with each other, and there is substantially no gap between adjacent spacer optical fibers (77); and A first optical fiber ribbon (60), comprising a first optical fiber array (75, 52), wherein: Each optical fiber of the first optical fiber array comprises a glass portion (74, 74A, 74B); and The glass portion (74, 74A, 74B) of each optical fiber (75, 52) of the first optical fiber array (75, 52) is combined with the first optical fiber array spacer (80, 80A, 80B), such that the longitudinal axes of the respective spacer optical fibers (77) are transverse to the longitudinal axes of the respective optical fibers (75, 52) of the first optical fiber array.

2. The optical fiber component (100, 300, 400) according to claim 1, further comprising a second optical fiber array spacer (80'), the second optical fiber array spacer (80') comprising: A second spacer optical fiber array (77'), wherein: Each spacer optical fiber of the second spacer optical fiber array (77') is combined with each other; and The second spacer optical fiber array (77') is combined with the first optical fiber array (75), such that the longitudinal axes of the respective spacer optical fibers of the second spacer optical fiber array (77') are transverse to the longitudinal axes of the respective optical fibers of the first optical fiber array (75), and the first optical fiber array (75) is disposed between the first optical fiber array spacer (80, 80A, 80B) and the second optical fiber array spacer (80').

3. The optical fiber component (100, 300, 400) according to claim 2, further comprising a second optical fiber ribbon (60B), the second optical fiber ribbon (60B) comprising a second optical fiber array (75'), wherein: Each optical fiber of the second optical fiber array (75') comprises a glass portion (74B); and The glass portion (74B) of each optical fiber of the second optical fiber array (75') is combined with the second optical fiber array spacer (80'), such that the longitudinal axes of the respective spacer optical fibers (77') of the second optical fiber array spacer (80') are transverse to the longitudinal axes of the respective optical fibers (75') of the second optical fiber array (75').

4. The optical fiber component (100, 300, 400) according to any one of claims 1-2, further comprising a second optical fiber ribbon (60B), the second optical fiber ribbon (60B) comprising a second optical fiber array (75'), wherein: The glass portion (74) of each optical fiber of the first optical fiber array (75) is combined with a first side of the first optical fiber array spacer (80); And The glass portion (74) of each optical fiber of the second optical fiber array (75') is combined with a second side of the first optical fiber array spacer (80).

5. The optical fiber assembly (300, 400) according to claim 1 further includes a second optical fiber array spacer (80B), and the second optical fiber array spacer (80B) includes: A second spacer optical fiber array (77'), wherein: Each spacer optical fiber of the second spacer optical fiber array (77') is bonded to each other; and The second spacer optical fiber array (77') is bonded to the first optical fiber array spacer (80A), such that the longitudinal axes of the respective spacer optical fibers of the second spacer optical fiber array (77') are transverse to the longitudinal axes of the respective spacer optical fibers of the first spacer optical fiber array (77).

6. The optical fiber component (100, 300, 400) according to any one of claims 1-5, wherein, The glass portion (74) of each optical fiber of the first optical fiber array (75, 52) is bonded to the first optical fiber array spacer (80, 80A, 80B) by an adhesive or laser bonding.

7. The optical fiber component (100, 300, 400) according to any one of claims 1-6, wherein, The first optical fiber array (75, 52) includes an interdigitated optical fiber array, and the interdigitated optical fiber array includes signal optical fibers (52) and lateral spacer optical fibers (79); and The lateral spacer optical fiber (52) is an optical fiber ferrule, wherein the signal optical fibers (52) and the lateral spacer optical fibers (79) of the interdigitated optical fiber array are bonded to each other.

8. The optical fiber component (100, 300, 400) according to any one of claims 1-7, wherein, The glass portion (74) of each optical fiber of the first optical fiber array (75, 52) is bonded to the first optical fiber array spacer (80, 80A, 80B), such that the longitudinal axes of the respective spacer optical fibers (77) of the spacer optical fiber array are perpendicular to the longitudinal axes of the respective optical fibers (75, 52) of the optical fiber array.

9. The optical fiber component (100, 300, 400) according to any one of claims 1-8 further comprises a connector body, wherein, The first optical fiber array spacer (80, 80A, 80B) is disposed within the connector body.

10. The optical fiber assembly (100, 300, 400) according to any one of claims 1-9, wherein: Each individual spacer optical fiber (77) of the first spacer optical fiber array (77) includes a first surface defining a first plane and a second surface defining a second plane parallel to the first plane; and The adhesive disposed between adjacent spacer optical fibers (77) does not extend beyond the first plane and the second plane.

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