Assembly technology for multi-fiber optical connectivity solutions

An assembly technology for a novel multi-fiber optical connectivity solution based on a V-groove alignment platform and microlens arrays was developed. Microlens array to substrate positioning by means of vision and of active alignment was employed for multi-mode fibers and single-mode fibers, respectively. A low-cost adhesive bonding technology was developed for attaching the microlens arrays to the substrates. Optical coupling losses (per lens transition) of well below 1 dB for multi-mode fibers, and below 0.5 dB for single mode fibers over 12 channels for 850 nm, 1300 nm and 1550 nm wavelength were achieved. Stable operation of the fiber/microlens assemblies during preliminary temperature cycling tests has been demonstrated. As the assembly process steps can be automated, this technology has potential to be employed for future low-cost multi-fiber optical connectivity solutions.