A fiber array module

Abstract

An aspect of the present disclosure relates to a fiber array module for precise alignment of a plurality of optical fibers, the module comprising: a first alignment block configured to support the optical fibers, the first alignment block including a plurality of alignment features for positioning the fibers in a pre-aligned configuration; a second alignment block comprising a plurality of holes, each hole configured to receive an individual optical fiber, the holes having oversized dimensions to facilitate insertion of the fibers; a connecting structure mechanically fixing the first alignment block and the second alignment block at a predetermined distance from each other, wherein: the first alignment block is configured to provide coarse alignment of the fibers, the oversized dimensions of the holes in the second alignment block allow for further adjustment of the fibers, and the predetermined distance between the first alignment block and the second alignment block provides a space that enables access by an external alignment tool, allowing fine alignment of the fibers within the holes of the second alignment block.

Description

[0001] Title: A fiber array module

[0002] Description:

[0003] TECHNICAL FIELD

[0004] The present invention generally relates to the field of fiber optic alignment and connectors and more particularly to the field of fiber array modules for precise optical fiber alignment in photonic systems.

[0005] BACKGROUND

[0006] Fiber optic communication systems have become indispensable in modern telecommunications, providing high-speed and high-capacity data transmission, but also in for example quantum optic computing, to transfer quantum information. The efficient alignment of optical fibers is critical to the performance of these systems, as even minor misalignments can result in significant signal loss or degradation. To address this, alignment assemblies incorporating components such as V-groove blocks and ferrules are widely used to position fibers in precise configurations for optical connections.

[0007] V-groove blocks are commonly employed as alignment tools due to their simplicity and ability to position fibers in predefined geometries. However, traditional V-groove configurations often struggle to achieve the level of precision required for advanced photonic applications. Variations in groove dimensions, fiber dimensions, fiber positioning, or mechanical tolerances can lead to inconsistencies in fiber alignment, particularly when connecting to components such as photonic chips or other fiber arrays. These inaccuracies can degrade the optical signal and limit the overall efficiency of the system.

[0008] It is therefore a goal of the present invention to provide an improved fiber array module that enhances the accuracy and reliability of V-groove-based fiber alignment while maintaining compatibility with ferrules and other optical components. By addressing the inherent limitations of traditional V-groove configurations, the invention aims to deliver a robust solution capable of supporting high-precision fiberalignment in modern photonic systems, thereby overcoming the above-mentioned disadvantages of the prior art at least in part.

[0009] SUMMARY

[0010] One aspect of the present invention relates to a fiber array module. A fiber array module may be understood as an assembly designed to align and fix optical fibers in a predefined configuration for precise optical coupling. Such modules typically include multiple components that enable the positioning, retention, and alignment of fibers with optical components such as ferrules, photonic chips and other fiber arrays.

[0011] The fiber array module according to the invention comprises a first alignment block , or also referred to as a pre-alignment block, configured to support the optical fibers. A first alignment block, or pre-alignment block, may be understood as a structural component with features designed to hold and organize optical fibers in an approximate position prior to their final alignment. This arrangement ensures that the fibers are initially constrained within specific tolerances, reducing the complexity of subsequent alignment steps. An effect of this arrangement is that the optical fibers are stabilized in a consistent manner, facilitating downstream precision coupling while avoiding the need for additional complex pre-alignment steps.

[0012] The fiber array module further comprises a second alignment block. The second alignment block may comprise a plurality of holes, each hole configured to receive an individual optical fiber, and the holes having oversized dimensions to facilitate insertion of the fibers. The second alignment block may however also be understood as a structural component containing openings or clearances that allow the fibers to be individually positioned and secured. While the second alignment block is preferably embodied as a ferrule with an array of oversized holes, it may alternatively be embodied as a V-groove array block. In this embodiment, the "holes" may be understood as clearances provided by the V-shaped or U-shaped grooves, which serve to guide and hold each individual fiber. In the case of a V-groove array block, the clearances within the grooves allow for fine alignment of the fibers by an external alignment tool, ensuring precise positioning within the grooves or other spacing provided by the second alignment block. With this alternative embodiment thebenefits of the oversized dimensions of a ferrule are retained, including facilitating easy fiber insertion, while also supporting precise adjustments during fine alignment.

[0013] In the configuration of the ferrule with holes, each hole is configured to receive an individual optical fiber, the holes having oversized dimensions to facilitate insertion of the fibers. Oversized holes may be understood as holes with diameters larger than the fibers they accommodate, providing a clearance that allows for adjustments during alignment. An effect of this arrangement is that fibers can be easily inserted into the holes without requiring excessive precision during initial handling, while still allowing precise positioning within the holes during alignment. This reduces handling time and increases manufacturing throughput and ease and preciseness of the alignment.

[0014] The fiber array module also includes a connecting structure mechanically fixing the first alignment block and the second alignment block at a predetermined distance from each other. A connecting structure may be understood as a mechanical element that links the two blocks while maintaining a fixed spatial relationship between them. This arrangement ensures that the alignment blocks remain stable relative to one another, creating a defined space between the blocks. An effect of this arrangement is that it establishes a consistent and repeatable configuration and predefined distance between the first and second alignment blocks (sufficient meaning; sufficient to allow space for the external alignment tool, while not too large of a spacing to compromise the initial, coarse alignment by the first alignment block), enabling tools or devices to access and manipulate the fibers in the intermediate space without interference or structural instability.

[0015] The fiber array module is characterized in that the first alignment block is configured to provide coarse alignment of the fibers, the oversized dimensions of the holes in the second alignment block allow for further adjustment of the fibers, and the predetermined distance between the first alignment block and the second alignment block provides a space configured and dimensioned to enable access by an external alignment tool to manipulate the fibers for precise alignment within the holes of the second alignment block. Coarse alignment may be understood as an approximate positioning of the fibers that reduces the degrees of freedom for subsequent alignment operations, as well as the range / stroke required for those subsequent alignment operations. An external alignment tool may be understood as adevice capable of fine manipulation of fibers to achieve their precise positioning. An effect of this arrangement is that the combination of coarse alignment, oversized holes, and predetermined spacing enables an efficient and effective alignment process. This approach enhances the precision and efficiency of aligning fibers with minimal reliance on tight tolerances for all components, thereby supporting scalable and cost-effective manufacturing.

[0016] The present invention provides a fiber array module that fundamentally departs from conventional single-step group alignment methods by employing a distinct two-stage alignment architecture. This architecture comprises a first alignment block configured for initial coarse positioning of a plurality of optical fibers, and a second alignment block designed to facilitate subsequent individual fine adjustment of each fiber. Crucially, a predetermined intermediate space is deliberately maintained between these two alignment blocks. This intermediate space is precisely configured and dimensioned to allow unobstructed access for an external alignment tool. This external alignment tool is specifically adapted to individually manipulate each fiber within the second alignment block to achieve precise fine alignment, a capability not taught or suggested by prior art solutions that focus on group alignment in a single step.

[0017] In an example, the fiber array module may be configured such that the optical fibers are unsupported in the space between the first alignment block and the second alignment block. It may be provided that this arrangement ensures that no structural elements interfere with the manipulation of the fibers in this space. An effect of this feature is that it enables precise adjustment of the fibers during alignment, as the alignment tool has unobstructed access to reposition the fibers without constraints.

[0018] The first alignment block serves to provide a coarse alignment, meaning an approximate positioning of the fibers that significantly reduces the degrees of freedom for subsequent alignment operations and limits the range of movement required for fine adjustment. In contrast, the second alignment block, with its oversized holes, is configured to enable individual fine alignment. This fine alignment is not merely a refinement of a group position, but rather a precise, per-fiber adjustment, allowing each optical fiber to be independently positioned for optimal optical coupling. This unique separation of coarse and individual fine alignment steps, facilitated by the external tool, represents a significant technical advantage over prior art systems.In an example, the first alignment block of the fiber array module may comprise a V-groove configuration to loosely position the fibers. A V-groove configuration may be understood as a series of grooves with sloping walls designed to hold fibers approximately in place. It may be provided that this arrangement guides the fibers into roughly aligned positions, reducing the complexity of their initial placement. An effect of this feature is the simplification of the assembly process while ensuring sufficient control for subsequent precise alignment steps.

[0019] The first alignment block may comprise alignment features, such as V-groove configurations with sloped walls, designed to loosely retain the fibers. This loose retention provides sufficient initial stability for the fibers while ensuring that they are not rigidly fixed. This inherent play is critical, as it allows for the necessary freedom of movement for each fiber during the subsequent individual fine adjustment step performed by the external alignment tool in the intermediate space. The design of these V-grooves, for instance with specified angles and pitches, can accommodate varying fiber diameters while consistently providing this crucial initial, yet nonconstraining, support.

[0020] In an example, the second alignment block may be a monolithic structure with an array of oversized holes for receiving individual fibers. A monolithic structure may be understood as a single-piece design that ensures consistent geometry and mechanical stability. It may be provided that this arrangement minimizes deformation and inaccuracies during the alignment process. An effect of this feature is that it enhances the overall reliability and precision of the fiber alignment module by reducing variability between components.

[0021] The second alignment block, which may be a monolithic ferrule, includes an array of holes with oversized dimensions. These oversized holes are not merely for ease of fiber insertion, but are specifically dimensioned to permit individual manipulation of each fiber by an external alignment tool. The clearance provided by these oversized dimensions allows the external tool to precisely adjust the position of each fiber within its respective hole, enabling fine-tuned optical alignment on a per-fiber basis. The ratio by which the hole diameter exceeds the fiber diameter (e.g., between 1.1:1 and 2.0:1 ) is carefully selected to ensure both sufficient manoeuvrability for the alignment tool and effective capillary action for subsequent adhesive application, thereby balancing ease of adjustment with robust, permanent fixation. Inan example, the connecting structure of the fiber array module may be a bridge-like element configured to mechanically connect the first and second alignment blocks. A bridge-like element may be understood as a structural component that spans the space between the alignment blocks while maintaining their relative positions. It may be provided that this arrangement ensures mechanical stability and preserves the spatial configuration of the module. An effect of this feature is that it provides a rigid yet accessible framework for alignment operations, improving both accuracy and ease of assembly.

[0022] The connecting structure, which may be a bridge-like element, mechanically fixes the first and second alignment blocks at a predetermined distance. This structure is configured to maintain the critical intermediate space, which is essential for external alignment tool access. In some embodiments, this connecting structure is affixed to the alignment blocks after the individual fine alignment of the fibers is completed. This sequence ensures that the flexibility required for precise per-fiber adjustment is available during the alignment process, while the final fixation provides robust and stable integration of the module components, securing the achieved high-precision alignment

[0023] In an example, the connecting structure may be configured to be affixed to the first alignment block and the second alignment block after the coarse and / or fine alignment of the fibers is completed. It may be provided that this arrangement allows for temporary adjustability during the alignment process and permanent fixation afterward. An effect of this feature is that it combines flexibility during setup with stability in the final configuration, ensuring precise and reliable alignment over the lifecycle of the module.

[0024] In an example, the connecting structure may form an integral or monolithic part with the first alignment block and the second alignment block. It may be provided that this arrangement eliminates the need for separate components, reducing assembly complexity. An effect of this feature is that it enhances structural rigidity and simplifies manufacturing while maintaining the precise spatial configuration necessary for fiber alignment.

[0025] In an example, the first alignment block may comprise a V-groove assembly consisting of a V-groove array block and a lid for securing the fibers in the grooves. A V-groove assembly may be understood as a combination of a base with V-shaped grooves and a cover that holds the fibers securely in place. It may be provided that this arrangement prevents the fibers from moving or dislodging during alignment operations. An effect of this feature is that it increases the reliability of the alignment process by maintaining consistent positioning throughout.

[0026] In an example, the first alignment block may comprise an array of holes, for place the fibers in the holes, which eliminates the step of applying and fixing a lid on top of the V-groove.

[0027] In an example, the second alignment block may be a ferrule comprising an array of oversized holes. The second alignment block may for example have a size of approximately 5 mm x 2 mm x 2 mm (width, length, height), for a 12 fiber array with a typical pitch of 250 pm. The skilled person will appreciate that for other arrays with larger or smaller number of fibers, a larger or smaller second alignment block may apply, with corresponding width, length, height and fiber pitch. A ferrule may be understood as a precision component designed to align and secure optical fibers. It may be provided that the oversized holes facilitate fiber insertion while allowing fine adjustments during alignment. An effect of this feature is that it improves ease of assembly and ensures precise alignment without requiring overly tight tolerances in the initial fiber placement.

[0028] In an example, the first alignment block may be configured for aligning a ribbon-shaped fiber configuration. A ribbon-shaped fiber configuration may be understood as a flat, parallel arrangement of multiple optical fibers. It may be provided that this arrangement enables efficient handling and alignment of high-density fiber arrays. An effect of this feature is the ability to streamline alignment processes for compact and high-capacity optical systems, reducing setup time while maintaining precision.

[0029] In an example, the first alignment block and the second alignment block of the fiber array module may be configured for a single row of parallel fibers, preferably 8, 12, 16, 20, 24, 28, 32, 36, 40, 44, 48 or 50 fibers. It may be provided that this arrangement supports applications requiring linear alignment of fibers, ensuring simplicity in design and compatibility with existing optical components. An effect of this feature is that it optimizes the alignment process for one-dimensional fiber arrays, reducing the complexity of assembly and achieving high precision in systems.In an example, the first alignment block and the second alignment block may be configured for a multi-row configuration of parallel fibers. It may be provided that this arrangement enables compact alignment of high-density fiber arrays, supporting applications that require greater bandwidth or functionality. An effect of this configuration is the efficient use of space, allowing for scalable optical connectivity while maintaining precise alignment across multiple rows.

[0030] In an example, the oversized dimensions of the holes in the second alignment block may be such that the diameter of the holes exceeds the diameter of the fibers by a ratio between 1.1:1 and 2.0:1. The oversized holes may be configured to accommodate fibers with diameter ranging approximately from 125 pm to 80 pm, and the diameter of the oversized hole may be defined as approximately 160 pm for a 125 pm fiber, in which configuration the holes have a pitch of approximately 250 pm. It may be provided that this clearance facilitates easy insertion of fibers while maintaining sufficient control for alignment. An effect of this feature is a balance between ease of assembly and alignment accuracy, reducing the risk of fiber damage while allowing precise positioning during fine alignment.

[0031] Within the context of the present disclosure, the fine alignment of the fibers may in an example be carried out using an external alignment tool or actuator system, for example as available from the applicant of the present invention. The actuator system or external alignment tool, is configured to manipulate each fiber within the oversized holes of the second alignment block. The actuator system may include precision-controlled actuators or cantilevers, capable of moving the fibers in multiple degrees of freedom, such as along the x, y, and z axes (preferably one of the these axes correspond with the longitudinal axis of the fibers), and / or rotating them about these axes. During this process, the position of each fiber may be measured using an optical measurement system, such as a camera or an interferometric sensor, to determine its alignment relative to an optical reference, such as a photonic chip, a reference marker, or a test optical beam. Based on the measured position, the actuator system may (iteratively) adjust the fiber's position until it reaches its optimal alignment. This optimal position may be defined as the point where the fiber achieves minimal insertion loss or maximal optical coupling efficiency with the target optical component. Once the optimal alignment is achieved, adhesive may be applied to the clearance space between the fiber and the inner wall of the oversized hole. The adhesive mayalso have been applied before the optimal alignment was achieved. The adhesive may then be cured, for example, using ultraviolet (UV) light or thermal curing, to permanently fix the fiber in its aligned position.

[0032] After alignment, the configuration of the oversized holes in the second alignment block allows fixing the fibers in their aligned positions by curing an adhesive applied within the oversized holes. The adhesive used for fixing the fibers during the curing process may preferably be selected to minimize thermal expansion, contraction, or shrinkage effects, thereby maintaining the alignment precision. This arrangement ensures that the module maintains its alignment accuracy despite thermal and mechanical stresses introduced during the curing process.

[0033] The choice of adhesive and the oversized hole diameter are interdependent, as adhesive shrinkage during curing can result in fiber displacement. Accordingly, the upper limit of the oversized hole diameter is determined by the extent of adhesive shrinkage, to ensure fibers remain fixed in their precise aligned positions post-curing. An effect of this feature is a balance between ease of assembly, alignment accuracy, and post-curing stability, reducing the risk of fiber damage or misalignment. The upper limit of the oversized hole diameter is additionally determined by the pitch of the holes in the ferrule, as the holes may not overlap, For a pitch of for example 250 pm, the diameter of the oversized holes must be smaller than 250 pm. In general the hole diameter must be smaller than the fiber array pitch to maintain the separation between adjacent holes.

[0034] The level of oversizing and the adhesive used for fixing the fibers in their aligned positions within the oversized holes of the second alignment block may be selected and configured based on the principle of capillary action. Capillary action may be understood as the ability of the liquid adhesive to flow into narrow spaces without the assistance of external forces, driven by the adhesive's surface tension and its interaction with the surfaces of the fibers and the walls of the oversized holes. To achieve effective capillary action, the oversized holes may be dimensioned such that the clearance between the fiber and the inner wall of the hole is within a range where adhesive wicking is optimized.

[0035] For optical fibers with diameters ranging from 50 pm to 400 pm, and for a typical adhesive, the clearance between the fiber and the wall of the hole may be selected to lie within 5 pm to 50 pm, e.g. for a 125 pm fiber the hole may have adiameter in the range of 135 pm to 225 pm, to obtain a clearance in the circumference of the fiber between 5 pm to 50 pm. This ensures that the adhesive can be uniformly distributed around the fiber by capillary forces while minimizing the risk of void formation or uneven coverage, which could otherwise compromise the alignment precision.

[0036] The surface finish and material properties of the inner wall of the oversized holes may also to some extent influence the capillary function. The inner wall surface for example may have a smoothness with an average roughness (Ra) between 0.2 pm and 0.8 pm to facilitate consistent adhesive flow. The material of the second alignment block may exhibit a hydrophilic nature, such as being made of a ceramic or polymer with a surface energy exceeding 30 mN / m, to promote adhesion and capillary action of the adhesive. Alternatively, the material of the second alignment block may be transparent, such as glass, to facilitate UV-curing. An additional coating may be applied to the inner walls of the oversized holes in the second alignment block to improve the hydrophilicity.

[0037] An effect thereof is that the adhesive is naturally drawn into the clearance space and encapsulates the fiber evenly during application, reducing manual adjustments and ensuring a strong, uniform bond after curing. Furthermore, the capillary function imposes an upper limit on the oversized hole diameter relative to the fiber, as excessive clearance would diminish the adhesive's ability to wick effectively and maintain uniform coverage.

[0038] In an example, the first alignment block may be configured to loosely retain the fibers without providing precise alignment. It may be provided that this arrangement simplifies the initial handling of the fibers, keeping them in a manageable configuration without imposing strict positioning constraints. An effect of this feature is that it reduces the complexity of the pre-alignment process, making the module suitable for applications requiring rapid assembly.

[0039] In an example, the predetermined distance between the first alignment block and the second alignment block may be between 5 mm and 30 mm, depending on the fiber diameter and alignment tool requirements. This predetermined distance is to be understood as the inner distance or spacing between the first and second alignment block. It may be provided that this spacing allows sufficient access for external alignment tools while maintaining mechanical stability. An effect of this featureis the optimization of the module for a range of fiber sizes and tool configurations, ensuring compatibility with diverse alignment processes.

[0040] In an example, the ratio of the distance between the first alignment block and the second alignment block to the diameter of the fibers may be between10:1 and 300:1, more preferable, it may be between 40:1 and 240:1. It may be provided that this ratio ensures an appropriate balance between accessibility for alignment tools and structural rigidity of the module. An effect of this feature is that it supports precise and efficient alignment while minimizing the risk of deformation or instability in the fibers.

[0041] In an example, the alignment features of the first alignment block may include grooves with sloped walls, each having an angle between 20° and 80°, to loosely hold fibers of varying diameters. The grooves may have a length ranging from 1 mm to 100 mm, more preferably ranging from 2 mm to 50 mm, even more preferably ranging from 5 mm to 30 mm, and more preferably approximately 15 mm. The pitch of the grooves may also be defined ranging from 1 time to 5 times the fiber diameter. It may be provided that this arrangement accommodates fibers with different geometries while ensuring their stability during alignment. An effect of this feature is the adaptability of the module to a wide range of fiber sizes, reducing the need for custom components for specific applications.

[0042] In an example, the fiber array module may be configured to maintain thermal stability during alignment to ensure precise positioning of the fibers. It may be provided that this arrangement minimizes the effects of thermal expansion or contraction, which could otherwise disrupt alignment accuracy. An effect of this feature is the improved reliability and performance of the module in environments with fluctuating temperatures, making it suitable for diverse operational settings.

[0043] In an example, the fiber array module may be adapted for optical fibers with diameters ranging from 50 pm to 400 pm, preferably ranging from 50 pm to 250 pm more preferably ranging from 60 pm to 200 pm, even more preferably ranging from 75 pm to 125 pm and most preferably approximately 125 pm or 80 pm. It may be provided that this range ensures compatibility with standard and specialized fiber sizes used in optical communication systems. An effect of this feature is the versatility of the module, enabling its use in a wide variety of applications without the need for significant modifications.In an alternative embodiment, the connecting structure may form an integral or monolithic part with the first alignment block and the second alignment block. This monolithic construction significantly enhances the structural rigidity and mechanical stability of the entire fiber array module, which is particularly beneficial for maintaining the precise spatial relationship required for the two-stage alignment process. By eliminating the need for separate components and assembly steps for the connecting structure, manufacturing complexity is reduced, and the risk of misalignment due to component tolerance stack-up or assembly errors is minimized. This integrated design ensures that the critical predetermined distance and the accessibility of the intermediate space for the external alignment tool are maintained with exceptional consistency.

[0044] The fiber array module may be configured for a multi-row arrangement of parallel fibers. While multi-row fiber arrays are known in the art, the combination with the present two-stage alignment architecture offers particular advantages. The ability to perform individual fine adjustment on each fiber using an external tool in the intermediate space becomes even more critical and beneficial in multi-row configurations, where precise alignment across multiple densely packed rows is typically more challenging. The dedicated accessible space ensures that even fibers in inner rows or densely populated areas can be individually accessed and finely adjusted, leading to superior alignment accuracy and coupling efficiency across the entire multi-row array compared to conventional multi-row systems.

[0045] The oversized dimensions of the holes in the second alignment block are such that the diameter of the holes exceeds the diameter of the fibers by a ratio typically between 1.1:1 and 2.0:1. This specific ratio is meticulously chosen to provide an optimal balance. On one hand, it ensures sufficient clearance for an external alignment tool to precisely manipulate individual fibers within the holes during the fine alignment stage. On the other hand, it maintains a sufficiently small gap to facilitate reliable adhesive wicking via capillary action, ensuring uniform encapsulation and secure, permanent fixation of the fibers after alignment. This carefully selected ratio is integral to achieving both the high precision of individual fiber adjustment and the longterm stability of the module.

[0046] The predetermined distance between the first alignment block and the second alignment block is carefully selected, for example, to be between 5 mm and30 mm. Furthermore, the ratio of this distance to the diameter of the optical fibers is maintained within a range, such as between 10:1 and 300:1, and more preferably between 40:1 and 240:1. These specific dimensions are critical for the functionality of the invention, as they ensure that the intermediate space is large enough to allow easy and unobstructed access for an external alignment tool to perform individual fine adjustments on each fiber. Simultaneously, these dimensions are optimized to maintain the mechanical stability of the overall module and prevent excessive fiber deflection that could compromise alignment accuracy, thereby enabling an effective and robust two-stage alignment process.

[0047] The fiber array module is configured to maintain exceptional thermal stability during the alignment process itself. While thermal stability is a general concern in optical systems, the present invention addresses it specifically within its two-stage alignment architecture. By separating the coarse and individual fine alignment steps, and providing an accessible intermediate space, the module design allows for the use of an external alignment tool that can compensate for minor thermal fluctuations during the fine adjustment phase. Moreover, the selection of materials for the alignment blocks and connecting structure, along with their specific geometric arrangement, is optimized to minimize differential thermal expansion / contraction effects across the two stages, ensuring that the precision achieved during individual fine alignment is maintained even under varying ambient conditions, thus providing a more robust and reliable alignment solution.

[0048] The module is adapted for use with optical fibers having a wide range of diameters, such as from 50 pm to 400 pm. This broad adaptability is a direct technical benefit of the inventive two-stage alignment architecture. Unlike systems relying on fixed-geometry V-grooves for precise final alignment, the present invention's use of oversized holes in the second alignment block, coupled with individual fine adjustment by an external tool, inherently accommodates variations in fiber diameter without requiring significant re-tooling or design changes. The external alignment tool can dynamically adapt its manipulation to different fiber sizes, ensuring high-precision alignment across the entire specified diameter range, which provides enhanced versatility and applicability for the module.

[0049] The present disclosure is described in conjunction with the appended figures. It is emphasized that, in accordance with the standard practice in the industry,various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.

[0050] In the appended figures, similar components and / or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a dash and a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label. The above and other aspects of the disclosure will be apparent from and elucidated with reference to the examples described hereinafter.

[0051] BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Figure 1 shows schematically an isometric view of an embodiment of a fiber array module according to the present disclosure;

[0053] Figures 2A and 2B shows schematically isometric views of two other embodiments of a fiber array module according to the present disclosure;

[0054] Figures 3A and 3B show schematically isometric views of yet two other embodiments of a fiber array module according to the present disclosure;

[0055] Figure 4A shows schematically an isometric view of elements of a fiber array module according to the present disclosure, before alignment of a plurality of optical fibers;

[0056] Figure 4B shows schematically an isometric view of elements of a fiber array module according to the present disclosure, after alignment of a plurality of optical fibers;

[0057] Figure 5 shows schematically a side view of elements of a fiber array module according to the present disclosure, including control elements for aligning a plurality of optical fibers.

[0058] DETAILED DESCRIPTION OF THE DRAWINGS

[0059] Figures 1 - 3 show different embodiments of a fiber array module 1 according to the present disclosure, wherein elements of the fiber array module 1before alignment and after alignment of a plurality of optical fibers are shown in figure 4A and 4B, respectively.

[0060] The fiber array module 1 is arranged for precise alignment of a plurality of optical fibers 2. In the embodiments of the figures, the plurality of optical fibers 2 have a ribbon-shaped fiber configuration provided in a single row of parallel fibers 2.

[0061] The fiber array module 1 comprises a first alignment block 3, a second alignment block 7, and a connecting structure 11, 1 T, 11” mechanically fixing the first alignment block 3 and the second alignment block 7 at a predetermined distance D from each other.

[0062] In the embodiment of figure 1, the connecting structure 11 is fixed to a top part of the first alignment block 3 and a top part of the second alignment block 7. In the embodiment of figure 2A, the connecting structure 11’ is fixed to a side part of the first alignment block 3 and the second alignment block 7, wherein in the embodiment of figure 2B, the connecting structure 11’ is fixed to both opposite side parts of the first alignment block 3 and the second alignment block 7.

[0063] In another embodiment, as shown in figure 3, the connecting structure 11” is formed as an integral or monolithic part with the first alignment block 3 and the second alignment block 7. The connecting structure 11” can extend on one side part of the first alignment block 3 and the second alignment block 7, as shown in figure 3A, or on both opposite side parts of the first alignment block 3 and the second alignment block 7, as shown in figure 3B.

[0064] The first alignment block 3, shown in more detail in figure 3A, is configured to support the optical fibers 2 and includes a plurality of alignment features 5 for positioning the fibers 2 in a pre-aligned configuration. The first alignment block 3 is configured to provide a coarse alignment of the fibers 2, configured to loosely retain the fibers without providing precise alignment. The alignment features 5 include a V-groove assembly consisting of a V-groove array block 15 to loosely position the fibers in the first alignment block 3. The alignment features 5 furthermore comprise a trench for holding the ribbonized section of the fiber array. The fibers in the grooves can be secured by a lid 17. The grooves are provided with sloped walls, each having an angle between 20° and 80°, to loosely hold optical fibers of varying diameters, for example with diameters ranging from 50 pm to 400 pm.The second alignment block 7 is a monolithic structure, for example a ferrule, with an array of oversized holes 9, wherein each hole 9 is configured to receive an individual optical fiber 2. The holes 9 having oversized dimensions to facilitate insertion of the fibers 2, wherein the diameter of the holes 9 exceeds the diameter of the fibers by a ratio between 1.1:1 and 2.0:1. The oversized dimensions of the holes 9 allow for further adjustment of the fibers 2.

[0065] The fiber array module 1 is configured to maintain thermal stability during alignment to ensure precise positioning of the fibers. The connecting structure 11, 11’, 11” is a bridge-like element and is mechanically connected to the first alignment block 3 and the second alignment block 7. This connecting structure may be mounted after the coarse and / or fine alignment of the fibers 2 is completed, thereby forming a connection between the first alignment block 3 and the second alignment block 7. Alternatively, this connecting structure 11” may form an integral or monolithic part together with the first alignment block 3 and the second alignment block 7, as shown in figures 3A and 3B.

[0066] The predetermined distance D between the first alignment block 3 and the second alignment block 7 provides a space, in which the optical fibers 2 are unsupported. The space enables access by an external alignment tool 13, as shown schematically in figure 5. This allows fine alignment of the fibers 2 within the holes 9 of the second alignment block 7, wherein the alignment of the fibers 2 can for example be observed by a camera module 17.

[0067] The predetermined distance D between the first alignment block 3 and the second alignment block 7 is between 5 mm and 30 mm, depending on the fiber diameter and alignment tool requirements, wherein the ratio of the distance between the first alignment block 3 and the second alignment block 7 to the diameter of the fibers 2 is between 10:1 and 300:1.

Claims

CLAIMS1. A fiber array module for precise alignment of a plurality of optical fibers, the module comprising:a first alignment block configured to support the optical fibers, the first alignment block including a plurality of alignment features for positioning the fibers in a pre-aligned configuration;a second alignment block comprising a plurality of holes, each hole configured to receive an individual optical fiber, the holes having oversized dimensions to facilitate insertion of the fibers;a connecting structure mechanically fixing the first alignment block and the second alignment block at a predetermined distance from each other, wherein:the first alignment block is configured to provide coarse alignment of the fibers,the oversized dimensions of the holes in the second alignment block allow for further adjustment of the fibers, andthe predetermined distance between the first alignment block and the second alignment block provides a space that enables access by an external alignment tool, allowing fine alignment of the fibers within the holes of the second alignment block.

2. The fiber array module according to claim 1, wherein the optical fibers are unsupported in the space between the first alignment block and the second alignment block.

3. The fiber array module according to claim 1, wherein the first alignment block comprises a V-groove configuration to loosely position the fibers.

4. The fiber array module according to claim 1, wherein the second alignment block is a monolithic structure with an array of oversized holes for receiving individual fibers.

5. The fiber array module according to claim 1, wherein the connecting structure is a bridge-like element configured to mechanically connect the first and second alignment blocks.

6. The fiber array module according to claim 1, wherein the connecting structure is configured to be affixed to the first alignment block and the second alignment block after the coarse and / or fine alignment of the fibers is completed.

7. The fiber array module according to claim 1, wherein the connecting structure forms an integral or monolithic part with the first alignment block and the second alignment block.

8. The fiber array module according to claim 3, wherein the first alignment block comprises a V-groove assembly consisting of a V-groove array block and a lid for securing the fibers in the grooves.

9. The fiber array module according to claim 1, wherein the second alignment block is a ferrule comprising an array of oversized holes.

10. The fiber array module according to claim 1 , wherein the first alignment block is configured for aligning a ribbon-shaped fiber configuration.

11. The fiber array module according to claim 1 , wherein the first alignment block and the second alignment block are configured for a single row of parallel fibers.

12. The fiber array module according to claim 1 , wherein the first alignment block and the second alignment block are configured for a multi-row configuration of parallel fibers.

13. The fiber array module according to claim 1, wherein the oversized dimensions of the holes in the second alignment block are such that the diameter of the holes exceeds the diameter of the fibers by a ratio between 1.1:1 and 2.0:1.

14. The fiber array module according to claim 1, wherein the first alignment block is configured to loosely retain the fibers without providing precise alignment.

15. The fiber array module according to claim 1 , wherein the predetermined distance between the first alignment block and the second alignment block is between 5 mm and 30 mm, depending on the fiber diameter and alignment tool requirements.

16. The fiber array module according to claim 1, wherein the ratio of the distance between the first alignment block and the second alignment block to the diameter of the fibers is between10:1 and 300:1.

17. The fiber array module according to claim 1, wherein the alignment features of the first alignment block include grooves with sloped walls, each having an angle between 20° and 80°, to loosely hold fibers of varying diameters18. The fiber array module according to claim 1, wherein the module is configured to maintain thermal stability during alignment to ensure precise positioning of the fibers19. The fiber array module according to claim 1, wherein the module is adapted for optical fibers with diameters ranging from 50 pm to 400 pm.

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