CA2031059C - Method of assembling multi-grooved silicon chip fiber optic terminations - Google Patents

Method of assembling multi-grooved silicon chip fiber optic terminations

Info

Publication number
CA2031059C
CA2031059C CA002031059A CA2031059A CA2031059C CA 2031059 C CA2031059 C CA 2031059C CA 002031059 A CA002031059 A CA 002031059A CA 2031059 A CA2031059 A CA 2031059A CA 2031059 C CA2031059 C CA 2031059C
Authority
CA
Canada
Prior art keywords
chips
fibers
holder
facing
major surfaces
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
CA002031059A
Other languages
French (fr)
Inventor
Rocco Bonanni
William Joseph Parzygnat
Roger Edward Weiss
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
AT&T Corp
Original Assignee
American Telephone and Telegraph Co Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by American Telephone and Telegraph Co Inc filed Critical American Telephone and Telegraph Co Inc
Application granted granted Critical
Publication of CA2031059C publication Critical patent/CA2031059C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Classifications

    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24Coupling light guides
    • G02B6/36Mechanical coupling means
    • G02B6/38Mechanical coupling means having fibre to fibre mating means
    • G02B6/3807Dismountable connectors, i.e. comprising plugs
    • G02B6/3833Details of mounting fibres in ferrules; Assembly methods; Manufacture
    • G02B6/3855Details of mounting fibres in ferrules; Assembly methods; Manufacture characterised by the method of anchoring or fixing the fibre within the ferrule
    • G02B6/3858Clamping, i.e. with only elastic deformation
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24Coupling light guides
    • G02B6/36Mechanical coupling means
    • G02B6/38Mechanical coupling means having fibre to fibre mating means
    • G02B6/3807Dismountable connectors, i.e. comprising plugs
    • G02B6/3833Details of mounting fibres in ferrules; Assembly methods; Manufacture
    • G02B6/3834Means for centering or aligning the light guide within the ferrule
    • G02B6/3838Means for centering or aligning the light guide within the ferrule using grooves for light guides
    • G02B6/3839Means for centering or aligning the light guide within the ferrule using grooves for light guides for a plurality of light guides
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24Coupling light guides
    • G02B6/36Mechanical coupling means
    • G02B6/38Mechanical coupling means having fibre to fibre mating means
    • G02B6/3807Dismountable connectors, i.e. comprising plugs
    • G02B6/3833Details of mounting fibres in ferrules; Assembly methods; Manufacture
    • G02B6/3855Details of mounting fibres in ferrules; Assembly methods; Manufacture characterised by the method of anchoring or fixing the fibre within the ferrule
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24Coupling light guides
    • G02B6/36Mechanical coupling means
    • G02B6/38Mechanical coupling means having fibre to fibre mating means
    • G02B6/3807Dismountable connectors, i.e. comprising plugs
    • G02B6/3833Details of mounting fibres in ferrules; Assembly methods; Manufacture
    • G02B6/3855Details of mounting fibres in ferrules; Assembly methods; Manufacture characterised by the method of anchoring or fixing the fibre within the ferrule
    • G02B6/3861Adhesive bonding
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24Coupling light guides
    • G02B6/36Mechanical coupling means
    • G02B6/38Mechanical coupling means having fibre to fibre mating means
    • G02B6/3807Dismountable connectors, i.e. comprising plugs
    • G02B6/3869Mounting ferrules to connector body, i.e. plugs
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/24Coupling light guides
    • G02B6/36Mechanical coupling means
    • G02B6/38Mechanical coupling means having fibre to fibre mating means
    • G02B6/3807Dismountable connectors, i.e. comprising plugs
    • G02B6/3833Details of mounting fibres in ferrules; Assembly methods; Manufacture

Abstract

Described is a method for assembling multi-fiber array connectors.
V-grooved silicon chips are placed in a holder which allows the chips to "float" with respect to each other and adjust to varying fiber diameters. Once the fibers areinserted, the chips are clamped and cemented together with the fibers fixed in the grooves.

Description

METHOD OF ASSEMBLING MULTI-GROOVED
SILICON CHIP FIBER OPTIC TERMINATIONS

Back~round of the Inv~..tio--This invention relates to optical fiber connections, and, in particular, to a 5 method of assembling connectors with fibers inserted therein.
Connectors for multi-fiber arrays typically include top and bottom silicon chips with V-shaped grooves formed in the facing major surfaces so that the fibers are positioned in the grooves. (See, e.g., U.S. Patent 4,725,120.) The usual method of assembling the connectors involves a stacking technique whereby the 10 fibers are first inserted in the grooves of the bottom chip and then the top chip is positioned over the bottom chip and fibers by means of a special fixture. The chips are then clamped and removed from the fixture to a position where an epoxy and heat are applied to bond the chips together. (See, e.g., U.S. Patent 4,379,771.)While such a technique is adequate, it would be desirable to simplify the 15 assembly by elimin~ting the need for a special fixture and thereby permit easier in~t~ ti~n of connectors in the field.
An alternative approach to assembling multi-fiber connectors involves inserting the fibers after the top and bottom chips are bonded together. A clampmember is typically provided around the chips, and an area of the bottom chip isexposed to permit insertion of the fibers. (See, e.g., U.S. Patent 4,818,059.) One of the drawbacks of such a technique is the fact that the chips are bonded together prior to fiber insertion. Consequently, even if a partially cured adhesive is used, it is difficult for the assembly to adjust to varying siæs of optical fibers within a ribbon or from ribbon-to-ribbon.
It is, therefore, an object of the invention to provide a simplified assembly technique for multi-fiber array connectors which adjusts to varying siæs of optical fiber.
Slm~qry of the Invention This and other objects are achieved in accordance with the invention, 30 which is a method of fabricating optical connectors where an array of optical fibers is held within grooves formed in facing major surfaces of a pair of chips. The method comprises providing a holder including said chips, said holder comprising a cantilevered section which aligns the chips but permits a variable space between the facing major surfaces of the chips. An array of optical fibers is inserted in the 35 grooves in the facing surfaces of the chips. The chips are then clamped so that the 2031 0~9 fibers are held within grooves formed in the facing surfaces of the chips, and the facing surfaces and fibers are then bonded together.
Brief Description of the D. ,.wi..~
These and other features of the invention are delint-~ted in detail in the 5 following description. In the drawings:
FM. 1 is a perspective view of a holder and a pair of chips which can be used in accordance with one embodiment of the invention;
FIG. 2 is a side view of the holder in FIG. l;
FIG. 3 is a perspective view illustrating one stage of assembly of a 10 connector in accordance with an embodiment of the invention;
FIG. 4 is a perspective view illustrating a further stage of assembly of a connector in accordance with the same embodiment;
FM. 5 is an end view of a portion of the connector in accordance with the same embodiment.
FIG. 6 is a perspective view illustrating a still further stage of assembly of a connector; and FIG. 7 is a top view of one of the chips of the connector.
It will be appreciated that, for purposes of illustration, these figures are not necess~rily drawn to scale.
20 Detailed Description FIGS. 1, 2, and 5 illustrate means which may be employed for assembling connectors in accordance with the invention. A holder, 10, is utilized for mounting therein a pair of silicon chips, 11 and 12. As more easily seen in FIG. 5, the top and bottom chips, 11 and 12, respectively, are of the standard type incl~l(ling 25 V-shaped grooves, e.g., 13 and 14, respectively, in the facing major surfaces of the chips. (See, e.g., U.S. Patent 4,818,058.) The chips typically are made of silicon, but could be other materials such as plastic. The chips typically measure approximately .76 by 6.3 by 5.84 mm and the grooves are typically app~o~ ately 100 llm deep and 140 llm wide. The grooves are usually formed by etching, 30 employing an anisotropic etching solution, but other techniques can be employed.
Returning to FIG. 1, it will be noted that at one end, the holder, 10, has an entrance section, 15, which in this example is funnel shaped for easy insertion of an optical fiber array. This opening would typically measure al)pl.-xi,.,~lely 7.4 by 4.3 mm for an array of 12 fibers.
The opposite opening of the holder, as also seen in the view in FIG. 2 comprises a cantilevered section including a pair of cantilevered arms, 16 and 17.
S Each arm includes seats, 18 and 19, for loosely holding the top and bottom chips, 11 and 12, respectively. The seats have essentially the same length and width as the chips so that the chips will be aligned in the x and y directions. The separation of the cantilevered members, 16 and 17, however, is such as to leave a small gap, typically less than the fiber diameter, between the two facing surfaces of the chips. Further, 10 since the cantilevered arms are free to flex slightly and/or the chips are only loosely mounted in the vertical (z) direction, the gap belween chips can vary as the fiber array is inserted therein. Thus, the chips "float" within the holder to allow the chips to be aligned by the fibers and to compel ~te for any variations in fiber diameter.
In some in~t~nces~ the top chip may be resting on the bottom chip prior 15 to insertion of the fibers. However, since the chips are free to move in the vertical (z) direction, the gap will vary as the fibers are inserted. On the other hand, if the gap is initially too large, the fibers in the ribbon may wander between the grooves in the chips. Consequently, the initial gap between the major surfaces of the chipsshould preferably be within the range 0 to 80 percent of the diameter of the fiber.
It will also be noted that the separation between the cantilevered and the funnel sections of the holder comprises walls, 20 and 21, which are chamfered. Such walls, together with chamfered edges, 22 and 23, of the silicon chips, permits easy insertion of the fiber array into the gap be~ween the chips. The fiber support grooves in the chip are also made wider at the end, as illustrated in FIG. 7, to facilitate easy 25 insertion of the fibers.
The holder is typically plastic made by a standard molding process.
Other m~t~ri~l~ could also be employed. The chips are inserted into the holder with the cantilevered section facing upward so that the chips fall into the seats, 18 and 19.
The end of the cantilevered section is then deformed, in this example by hP~ting, so 30 that dimples, 24 and 25, are formed to keep the chips within the holder whilein~ ing the loose retention of the chips between the cantilevered members, 16 and 17.
The assembly of the connector in the field starts with the holder and silicon chips mounted therein as previously described. A ribbon, 30, of FIG. 3 35 including an array of fibers, e.g., 31, is p~,pared by stripping off any protective covering at the ends of the fibers. The ribbon is then inserted into the entrance 20310~9 opening, 15, of the holder as shown in FIG. 3 so that the stripped portions of the fibers lie within the grooves formed between the top and bottom silicon chips. As mentioned previously, the gap between the major snrf~ces of the chip will vary as the fibers are inserted due to the flexing of the cantilevered arms and/or flo~,ting of 5 the chips so that fibers of varying sizes will fit within the gap. In one example, the ribbon in~luded 12 fibers each with a core ~ mPter of 62.5 llm and an outer tli~mPter of 125 ~m. Typically, the gap between the major surfaces of the chips will vary between 12 to 100 ~m during such fiber insertion.
Once the fibers are inserted, as illustrated in FM. 4, the floating chips, 10 11 and 12, are clamped shut so that the fibers are seated within their appl~liate grooves. The particular method described here utilizes a simple alligator clip, 32, to deflect the cantilevered arms against the chips, but any type of clamping mech~ni~m can be employed. While the chips are thus clamped, a bonding adhesive (not shown) is applied in order to bond the top and bottom chips together and to fix the fibers 15 within the grooves. This is accomplished, typically, by applying several drops of a low viscosity epoxy to the fibers in the vicinity of the chip and allowing the adhesive to wick into the chip openings. The particular adhesive employed was an epoxy such as that sold by Buehler Ltd. However, many standard bonding agents can be employed. Alt~rn~tively, the surfaces of the chips could be coated with a B-stage 20 epoxy prior to assembly. Subsequent to fiber insertion, the assembly could be heated in order to melt and cure the epoxy.
Subsequent to the bonding operation, the portion of the fibers exten-ling out past the chips can be cut and polished according to standard techniques, resulting in the structure shown in FIG. 6. An al)plopliate housing, 33, and other parts, can 25 then be placed around the resulting assembly to form a termination which can be mated with another termin~tion of the same design. (See, e.g., U.S. Patent 4,725,120 and U.S. Patent 4,818,058.) Thus, it will be appreciated that, in accordance with the invention, a multi-fiber array connector plug can be assembled easily according to particular30 needs without a special fixture. An additional advantage of the method lies in the ability to check for broken fibers during the assembly process. This is accomplished by lightly tugging on the fiber ribbon after lightly clamping the chips so that the fiber ribbon can be moved longitu-lin~lly with respect to the chips. Any broken fibers can, thel~;r(jle, be observed since they will not move along with the unbroken fibers in the 35 ribbon. The ribbon can, thelGfol~i, be replaced prior to celllen~illg the chips, thus saving the chips from destruction in the event of a defective fiber.

Various mo lific~fion~ will become a~Gnt to those skilled in the art.
For example, the holder, 10, can be ~lesi~nto~l to be removable after the chips are clamped and bonded together. All such variations which basically rely on the teachings through which the invention has advanced the art are plL~elly considered 5 within the scope of the invention.

Claims (10)

1. A method of fabricating optical connectors where an array of optical fibers is held within grooves formed in facing major surfaces of a pair of chipscomprising the steps of:
providing a holder including said chips, said holder comprising a cantilevered section which aligns the chips but permits a variable space between the facing major surfaces of the chips;
inserting an array of optical fibers in the grooves in the facing surfaces of the chips;
clamping the chips so that the fibers are held within the grooves formed in the facing surfaces of the chips; and bonding the facing surfaces of the chips together.
2. The method according to claim 1 wherein the holder includes said cantilevered section at one end and an enlarged opening at an opposite end.
3. The method according to claim 1 wherein the chips comprise silicon.
4. The method according to claim 2 wherein between the cantilevered section and enlarged opening is a wall which is chamfered.
5. The method according to claim 1 further comprising the step of pulling on the array after lightly clamping the chips and prior to bonding the chips in order to test for broken fibers.
6. The method according to claim 1 further comprising the step of providing a housing surrounding said holder subsequent to bonding said chips so that the resulting assembly can be mated with a similar assembly to couple light between the fibers of the assemblies.
7. The method according to claim 1 wherein the spacing between the major surfaces of the chips can vary within the range of 0 to 80 percent of the fiber diameter prior to insertion of the fibers therein.
8. The method according to claim 1 wherein the cantilevered section includes a pair of opposite cantilevered arms, each including a seat within which one of said chips is mounted.
9. The method according to claim 1 wherein the entrance edges of the chips comprise a chamfer and an enlarged fiber guidance groove.
10. The method according to claim 1 wherein the spacing between the major surfaces of the chips can vary within the range 12 to 100 µm during theinsertion of the fibers.
CA002031059A 1990-02-27 1990-11-28 Method of assembling multi-grooved silicon chip fiber optic terminations Expired - Lifetime CA2031059C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US07/486,045 US4998796A (en) 1990-02-27 1990-02-27 Method of assembling multi-grooved silicon chip fiber optic terminations
US486,045 1990-02-27

Publications (1)

Publication Number Publication Date
CA2031059C true CA2031059C (en) 1995-03-14

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CA002031059A Expired - Lifetime CA2031059C (en) 1990-02-27 1990-11-28 Method of assembling multi-grooved silicon chip fiber optic terminations

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US (1) US4998796A (en)
EP (1) EP0444347B1 (en)
JP (1) JP3042724B2 (en)
CA (1) CA2031059C (en)
DE (1) DE69020136T2 (en)

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Also Published As

Publication number Publication date
EP0444347B1 (en) 1995-06-14
US4998796A (en) 1991-03-12
JPH04216512A (en) 1992-08-06
EP0444347A3 (en) 1992-04-22
EP0444347A2 (en) 1991-09-04
JP3042724B2 (en) 2000-05-22
DE69020136T2 (en) 1995-10-26
DE69020136D1 (en) 1995-07-20

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