Axsun Technologies, Inc.

Corning Lasertron, Incorporated

Lasertron

Corning Laserton, Inc.

Steven David Conover

Thomas Chaodung Yang

Randal A Murdza

Wayne F Sharfin

Jeffrey Korn

Walid A Atia

Eric E Fitch

Sean P O'Connor

Lee-Ching Hwu

Margaret A Stern

A micro-optical train manufacturing process includes a step of characterizing the position of optical components on an optical bench, typically using a metrology system. These optical components are then aligned with respect to each other in a passive alignment step based on data from the metrology system and optical system design information. As a result, a subsequent active align process can be avoided in some situations, or if a subsequent active alignment process is performed, the time required for that active alignment process can be reduced because of this initial metrology-based passive alignment step.

Optical component installation and train alignment process utilizing metrology and plastic deformation

A process for assembling micro-optical systems, such as optoelectronic and/or fiber optic components uses solder self-alignment to achieve a coarse, passive alignment of optical components relative to the optical bench. The fine, final alignment is performed using plastic deformation of the optical components to thereby improve the alignment of the optical components. As a result, the sub-micrometer alignment accuracies are attainable, if required.

Manufacturing system using solder self-alignment with optical component deformation fine alignment

An endface configuration of an optical fiber has a frustum region which is produced by polishing the endface. In order to produce the optimal rounded tip, however, the polished fiber is then fused. To increase coupling efficiency, the vertex angle of the polished frustum region is acute, preferably between 16 and 20&deg;. Further, to create a hyperbolic endface surface, an intermediate frustum region is preferably polished prior to fusing tip. This fused tip is preferably has a circular cross-section.

Polished fused optical fiber endface

An improved fiber endface shape for increasing coupling of optical power from a source into fiber and its manufacture are disclosed. The inventive tip comprises a cleaved end surface that is preferably substantially orthogonal to the fiber's axis and a first and second polished, angled surfaces intersecting the end surface. Break-lines between the angled surfaces and the end surface fall near an edge of a cladding-core interface and preferably outside that interface when the fiber and transmitted light are such that a substantial portion of the light is transmitted in the cladding. A spatial intensity profile of light exiting from the tip is detected during manufacture and is used to monitor the polishing of the angled surfaces. Tests have shown that the inventive tip achieves the coupling efficiency associated with the double-angled wedge-shaped fiber tips while maintaining much of the ease of manufacture associated with the single-angle wedge tips.

Flat top, double-angled, wedge-shaped fiber endface

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Chelmsford, MA, United States of America

Steven David Conover