CN115407463B - Optical device and assembly method thereof - Google Patents

Abstract

The present disclosure provides an optical device including a first optical fiber set and a second optical fiber set, and a method of assembling the same. The first optical fiber group has a first end portion and a second end portion opposite to the first end portion, and includes a plurality of first optical fibers arranged side by side with each other. The second optical fiber group has a third end portion and a fourth end portion opposite to the third end portion, and includes a plurality of second optical fibers arranged side by side with each other, wherein a length of each of the plurality of second optical fibers is greater than a length of each of the plurality of first optical fibers.

Description

Optical device and assembly method thereof

Technical Field

The present disclosure relates to an optical device and an assembly method thereof, and in particular to an optical device of a silicon photonics chip and an assembly method thereof.

Background technique

Ribbon optical fiber is widely used in current data center networks due to its advantages such as dense transmission, convenient splicing, simple splicing of multiple optical fibers, and cost-saving installation.

With the widespread popularity of ribbon optical fibers, the quality of the connection between the ribbon optical fibers and optical devices must also be stable to improve the reliability of optical transmission signals. Therefore, it is necessary to improve the current ribbon optical fibers and their assembly methods to improve the transmission efficiency of optical devices and reduce production costs.

The above “prior art” description is only to provide background technology, and does not admit that the above “prior art” description reveals the subject matter of the present disclosure, does not constitute the prior art of the present disclosure, and any description of the above “prior art” should not be regarded as any part of this case.

Summary of the invention

An embodiment of the present disclosure provides an optical device, which includes a first optical fiber group and a second optical fiber group. The first optical fiber group has a first end and a second end opposite to the first end, and includes a plurality of first optical fibers arranged side by side with each other. The second optical fiber group has a third end and a fourth end opposite to the third end, and includes a plurality of second optical fibers arranged side by side with each other, wherein the length of each of the plurality of second optical fibers is greater than the length of each of the plurality of first optical fibers.

In some embodiments, each of the plurality of second optical fibers has a different length from the other.

In some embodiments, the length of the second optical fiber group is greater than the length of the first optical fiber group.

In some embodiments, a distance between the first end and the third end is greater than a distance between the second end and the fourth end.

In some embodiments, portions of the plurality of first optical fibers are coplanar with each other, and portions of the plurality of second optical fibers are coplanar with each other.

In some embodiments, the optical device further comprises a first colloid and a second colloid, wherein the first colloid fixes a portion of the first optical fiber group, and the second colloid fixes a portion of the second optical fiber group.

In some embodiments, the optical device further includes an optical receiver-transmitter, which couples the first end and the third end. The first end is an optical signal receiving end, and the third end is an optical signal transmitting end.

In some embodiments, the optical transmitter and receiver includes an optical waveguide to receive an optical signal from the first optical fiber group or transmit an optical signal to the second optical fiber group.

One embodiment of the present disclosure provides another optical device, which includes a first optical fiber group and a second optical fiber group. The first optical fiber group has a first end and a second end opposite to the first end, and includes a plurality of first optical fibers arranged side by side with each other. The second optical fiber group has a third end and a fourth end opposite to the third end, and includes a plurality of second optical fibers arranged side by side with each other. The distance between the first optical fiber group and the second optical fiber group varies along the length direction of the first optical fiber group or the second optical fiber group.

In some embodiments, the second optical fiber group has an angle greater than 0 degrees relative to the first optical fiber group.

Another embodiment of the present disclosure provides a method for forming an optical device, including: providing a first substrate having a first groove and a second groove, the first groove including a first endpoint and a second endpoint relative to the first endpoint, and the second groove including a third endpoint and a fourth endpoint relative to the third endpoint; placing a plurality of first optical fibers in the first groove and a plurality of second optical fibers in the second groove, respectively; covering a second substrate on the first substrate; and performing a pre-forming step to bond the plurality of first optical fibers to form a first optical fiber group, and to bond the plurality of second optical fibers to form a second optical fiber group.

In some embodiments, after placing the plurality of first optical fibers in the first trench and the plurality of second optical fibers in the second trench respectively, the plurality of first optical fibers are arranged side by side and adjacent to each other, and the plurality of second optical fibers are arranged side by side and adjacent to each other.

In some embodiments, the first groove restricts lateral movement of the plurality of first optical fibers, and the second groove restricts lateral movement of the plurality of second optical fibers.

In some embodiments, the first groove has a first arc-shaped edge, and the second groove has a second arc-shaped edge, and the first arc-shaped edge and the second arc-shaped edge respectively define the extension directions of the plurality of first optical fibers and the plurality of second optical fibers.

In some embodiments, the distance between the first arcuate edge and the second arcuate edge varies along the length direction of the first groove or the second groove.

In some embodiments, after covering the second substrate on the first substrate, the second substrate presses the first optical fibers in the first groove and the second optical fibers in the second groove so that the first optical fibers and the second optical fibers are coplanar with each other.

In some embodiments, the method of forming an optical device further includes providing a first fixture and a second fixture to respectively fix two ends of the plurality of first optical fibers, and providing a third fixture and a fourth fixture to respectively fix two ends of the plurality of second optical fibers.

In some embodiments, the preforming step includes coating the plurality of first optical fibers and the plurality of second optical fibers with an adhesive, and forming a first colloid and a second colloid respectively after the adhesive is cured.

In some embodiments, after the pre-forming step, the second substrate and the first substrate are removed.

In some embodiments, the method of forming an optical device further includes cutting a portion of the first optical fiber group, and cutting a portion of the second optical fiber group.

Therefore, the present disclosure proposes a novel optical device assembly method, which pre-shapes and bonds multiple optical fibers to form an optical fiber group with a pre-defined shape. The formed optical fiber group can have both the flexibility of a single optical fiber and the strength of an optical fiber group. Multiple optical fiber groups can have optical signal transmitting or receiving ends required to match the optical receiver transmitter. Therefore, the optical fiber group can be easily combined with the optical signal transmitting or receiving end required by the optical receiver transmitter, further reducing the stress effect at the coupling interface between the optical receiver transmitter and the corresponding optical signal transmitting or receiving end, improving the problem of excessive stress when the optical signal transmitting or receiving end of the unshaped optical fiber group is coupled with the optical receiver transmitter, and thus improving the reliability of the optical device.

The above has been a fairly broad overview of the technical features and advantages of the present disclosure, so that the detailed description of the present disclosure below can be better understood. Other technical features and advantages that constitute the subject matter of the claims of the present disclosure will be described below. It should be understood by those with ordinary knowledge in the technical field to which the present disclosure belongs that the concepts and specific embodiments disclosed below can be used to modify or design other structures or processes to achieve the same purpose as the present disclosure. It should also be understood by those with ordinary knowledge in the technical field to which the present disclosure belongs that such equivalent constructions cannot depart from the spirit and scope of the present disclosure as defined by the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the disclosure of the present application may be obtained by referring to the embodiments and claims in conjunction with the drawings, in which the same reference numerals refer to the same elements.

FIG. 1 is an exploded schematic diagram of an optical device in the prior art.

FIG. 2 is a cross-sectional view of the first optical fiber group and the second optical fiber group shown in FIG. 1 .

FIG. 3 is an exploded schematic diagram of another optical device in the prior art.

FIG. 4 is a schematic diagram of an optical device according to some embodiments of the present disclosure.

FIG. 5 is a cross-sectional view of a first optical fiber group and a second optical fiber group drawn according to FIG. 4 in accordance with some embodiments of the present disclosure.

FIG. 6 is a schematic diagram showing the lengths of a plurality of first optical fibers and a plurality of second optical fibers according to some embodiments of FIG. 4 .

FIG. 7 is a flow chart of an optical device assembly method according to some embodiments of the present disclosure.

8 to 21 are schematic diagrams of operation steps drawn according to the optical device assembly method of FIG. 7 in accordance with some embodiments of the present disclosure.

The reference numerals are described as follows:

10, 110: First optical fiber group

20, 120: Second optical fiber group

30, 130: Optical receiver transmitter

12, 112: First Fiber

22, 122: Second optical fiber

32, 132: Optical signal receiving end

34, 134: Optical signal transmitter

40, 140: Fiber Optic Connector

42, 142: First joint

44, 144: Second joint

50, 150: First colloid

60, 160: Second colloid

101, 103, 105, 107, 109, 111, 113, 115: Steps

180: First substrate

182: First Groove

184: Second groove

180S: Extrusion Department

180P: protrusion

190: Second substrate

200: Methods

A1, T1: First end

A2, T2: Second end

A3, T3: The third end

A4, T4: Fourth end

C1, C2: cutting direction

D1, L1: distance

E1: First endpoint

E2: Second endpoint

E3: The third endpoint

E4: The fourth endpoint

J1: First fixture

J2: Second fixture

J3: Third fixture

J4: Fourth fixture

O1, O2, P1: Optical devices

S1: First curved edge

S2: Second curved edge

W1: First width

W2: Second width

Z1: Direction

Detailed ways

The embodiments of the present disclosure are discussed in detail below. However, it should be understood that the embodiments provide many applicable inventive concepts that can be implemented in various specific environments. The specific embodiments discussed only illustrate the specific ways to make and use the embodiments and do not limit the scope of the present disclosure.

In the various views and illustrative embodiments, the same reference numerals are configured to represent the same elements. Reference will now be made in detail to the exemplary embodiments shown in the drawings. Whenever possible, the same reference numerals are used in the drawings and the specification to represent the same or similar parts. In the drawings, the shapes and thicknesses may be exaggerated for clarity and convenience. This description will be particularly directed to elements that form a part of the device according to the present disclosure or cooperate more directly with it. It should be understood that elements that are not specifically shown or described can take various forms. References throughout this specification to "some embodiments" or "embodiments" mean that specific features, structures or characteristics described in conjunction with the embodiment are included in at least one embodiment. Therefore, the phrases "in some embodiments" or "in embodiments" that appear in various places throughout this specification do not necessarily refer to the same embodiment. In addition, specific features, structures or characteristics can be combined in any suitable manner in one or more embodiments.

In the accompanying drawings, the same reference numerals are configured to indicate the same or similar elements in various views, and illustrative embodiments of the present invention are shown and described. The drawings are not necessarily drawn to scale, and in some cases, the drawings have been exaggerated and/or simplified and are configured only for illustrative purposes. Based on the following illustrative embodiments of the present invention, those of ordinary skill in the art will understand many possible applications and variations of the present invention.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as those commonly understood by those skilled in the art to which the embodiments of the present disclosure belong. It should be understood that terms such as those defined in commonly used dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant art and the present disclosure, and should not be understood or construed as having an overly formal meaning unless explicitly defined herein.

In addition, the following provides multiple embodiments of the present disclosure as examples to illustrate the core value of the present disclosure, but it is not intended to limit the scope of protection of the present disclosure. For the sake of clarity and ease of understanding, the same or similar functions or elements between different embodiments of the present disclosure will not be repeatedly described or shown in the figures. And different elements or technical features in different embodiments, under the premise of not conflicting with each other, are combined or replaced to obtain a new embodiment, which still falls within the scope of protection of the present disclosure.

Referring to FIG. 1 , FIG. 1 is an exploded schematic diagram of an optical device O1. The optical device O1 comprises a first optical fiber group 10, a second optical fiber group 20, an optical receiving transmitter 30, and an optical fiber connector 40. The first optical fiber group 10 has a first end A1 and a second end A2 relative to the first end A1, and the second optical fiber group 20 has a third end A3 and a fourth end A4 relative to the third end A3. The first optical fiber group 10 and the second optical fiber group 20 are both straight and have the same length. When the first optical fiber group 10 and the second optical fiber group 20 are placed in parallel, the distance between the first end A1 and the third end A3 is equal to the distance between the second end A2 and the fourth end A4.

The optical receiver transmitter 30 can be connected to the optical signal receiving end 32 and the optical signal emitting end 34. The optical fiber connector 40 has a first connector 42 and a second connector 44. The distance between the optical signal receiving end 32 and the optical signal emitting end 34 of the optical receiver transmitter 30 is equal to the distance between the first connector 42 and the second connector 44 of the optical fiber connector 40. When the optical device O1 is assembled, the first end A1 of the first optical fiber group 10 is connected to the optical signal receiving end 32, the third end A3 of the second optical fiber group 20 is connected to the optical signal emitting end 34, and the optical signal receiving end 32 and the optical signal emitting end 34 are coupled to the optical receiver transmitter 30. On the other hand, the second end A2 of the first optical fiber group 10 is connected to the first connector 42 of the optical fiber connector 40, and the fourth end A4 of the second optical fiber group 20 is connected to the second connector 44 of the optical fiber connector 40.

Referring to Fig. 2, Fig. 2 is a cross-sectional view of the first optical fiber group 10 and the second optical fiber group 20 shown in Fig. 1. The first optical fiber group 10 includes a plurality of first optical fibers 12 arranged side by side with each other, and the second optical fiber group 20 includes a plurality of second optical fibers 22 arranged side by side with each other. The plurality of first optical fibers 12 and the plurality of second optical fibers 22 are fixed by the first colloid 50 and the second colloid 60, respectively, to form the first optical fiber group 10 including the plurality of first optical fibers 12 arranged adjacently and the second optical fiber group 20 including the plurality of second optical fibers 22 arranged adjacently.

Refer to FIG3, which is a schematic diagram of another optical device O2. Since the specifications of optical transmitters and receivers produced by different manufacturers are not the same, the distance between the optical signal inlet and the optical signal outlet (not shown) of the optical transmitter and receiver 30 may vary from manufacturer to manufacturer. Taking FIG3 as an example, when the optical signal inlet and the optical signal outlet of the optical transmitter and receiver 30 are coupled to the optical signal transmitting end 34 and the optical signal receiving end 32 respectively, the distance between the optical signal receiving end 32 and the optical signal transmitting end 34 may not be equal to the distance between the first connector 42 and the second connector 44 of the optical fiber connector 40. The difference between FIG3 and FIG1 is that the distance between the optical signal receiving end 32 and the optical signal transmitting end 34 is greater than the distance between the first connector 42 and the second connector 44 of the optical fiber connector 40. When the first optical fiber group 10 and the second optical fiber group 20 are coupled to the optical transmitter and receiver 30 and the optical fiber connector 40 at the same time, the first optical fiber group 10 and the second optical fiber group 20 must be bent and deviate from the straight line to complete the coupling.

In the process of bending the first optical fiber group 10 and the second optical fiber group 20, since the adjacently arranged plurality of first optical fibers 12 and the plurality of second optical fibers 22 have been fixed by the first colloid 50 and the second colloid 60 respectively, and the bending degree of each optical fiber is different, when the first optical fiber group 10 and the second optical fiber group 20 are to be coupled with the optical receiver transmitter 30 and the optical fiber connector 40 at the same time, there will be a large torque in the first optical fiber group 10 and the second optical fiber group 20, resulting in incomplete connection with the optical receiver transmitter 30 or the optical fiber connector 40, resulting in that the optical signal cannot be reliably transmitted from the optical signal receiving end 32 and the optical signal transmitting end 34 of the optical receiver transmitter 30 to the first optical fiber group 10 or the second optical fiber group 20, or from the first optical fiber group 10 and the second optical fiber group 20 to the optical signal receiving end 32 or the optical signal transmitting end 34, thereby causing reliability problems of the optical device O2.

The present disclosure provides an optical device and an assembly method thereof, so as to improve the problem of excessive torque after a plurality of optical fiber groups are simultaneously coupled with an optical transmitter and receiver and an optical signal transmitting end and an optical signal receiving end.

Referring to Fig. 4, Fig. 4 is a schematic diagram of an optical device P1 according to some embodiments of the present disclosure. In some embodiments, the optical device P1 comprises a first optical fiber group 110, a second optical fiber group 120, an optical receiving transmitter 130, and an optical fiber connector 140. In some embodiments, the first optical fiber group 110 has a first end T1 and a second end T2 relative to the first end T1, and the second optical fiber group 120 has a third end T3 and a fourth end T4 relative to the third end T3.

In some embodiments, the first optical fiber group 110 and the second optical fiber group 120 are ribbon fibers. In some embodiments, the first optical fiber group 110 includes a plurality of first optical fibers 112, and the second optical fiber group 120 includes a plurality of second optical fibers 122. In some embodiments, the length of the first optical fiber group 110 is the length of the longest first optical fiber 112 among the plurality of first optical fibers 112. In some embodiments, the length of the second optical fiber group 120 is the length of the longest second optical fiber 112 among the plurality of second optical fibers 122. In some embodiments, the length of the first optical fiber group 110 is different from the length of the second optical fiber group 120. In some embodiments, the length of the second optical fiber group 120 is greater than the length of the first optical fiber group 110. In some embodiments, the distance between the first end T1 of the first optical fiber group 110 and the third end T3 of the second optical fiber group 120 is greater than the distance between the second end T2 of the first optical fiber group 110 and the fourth end T4 of the second optical fiber group 120.

In some embodiments, the optical transmitter-receiver 130 may include a silicon photonics chip or an optical engine, which can convert an electrical signal into an optical signal or convert an optical signal into an electrical signal, and transmit the signal through an optical signal inlet and outlet (not shown). In some embodiments, the first end T1 of the first optical fiber group 110 is first combined with the optical signal receiving end 132 and the third end T3 of the second optical fiber group 120 is first combined with the optical signal transmitting end 134, and then the optical signal receiving end 132 and the optical signal transmitting end 134 are coupled to the optical transmitter-receiver 130. In some embodiments, the optical transmitter-receiver 130 includes at least one optical waveguide (not shown) to receive an optical signal from the first optical fiber group 110 or transmit an optical signal to the second optical fiber group 120.

In some embodiments, the optical fiber connector 140 may be an MT type connector (mechanical transfer ferrule, referred to as MT ferrule) having a rectangular appearance. In some embodiments, the optical fiber connector 140 may accommodate a 1x2, 1x4, 1x6, 1x8, 1x10 or 1x12 optical fiber array. In some embodiments, the optical fiber connector 140 has a first connector 142 and a second connector 144, which are connected to the second end T2 of the first optical fiber group 110 and the fourth end T4 of the second optical fiber group 120, respectively. In some embodiments, the distance between the optical signal receiving end 132 and the optical signal emitting end 134 is greater than the distance between the first connector 142 and the second connector 144. In such an embodiment, the optical signal receiving end 132 is not substantially aligned with the first connector 142, and the optical signal emitting end 134 is not substantially aligned with the second connector 144. In some embodiments, the extension direction of the optical signal receiving end 132 and the extension direction of the first connector 142 have an angle greater than 0 degrees. In some embodiments, the extension direction of the optical signal transmitting end 134 and the extension direction of the second connector 144 have an angle greater than 0 degrees.

Continuing to refer to FIG. 4 , in some embodiments, the distance D1 between the first optical fiber group 110 and the second optical fiber group 120 may vary along the length direction of the first optical fiber group 110 or the second optical fiber group 120. Taking FIG. 4 as an example, the distance D1 may gradually increase from the optical fiber connector 140 toward the optical receiver transmitter 130. In other embodiments, the distance D1 may gradually decrease from the optical fiber connector 140 toward the optical receiver transmitter 130. In some embodiments, the second optical fiber group 120 is not parallel to the first optical fiber group 110, and the second optical fiber group 120 has an angle greater than 0 degrees relative to the first optical fiber group 110.

Referring to FIG. 5 , FIG. 5 is a cross-sectional view of the first optical fiber group 110 and the second optical fiber group 120 according to some embodiments of FIG. 4 . In some embodiments, the first optical fiber group 110 includes a plurality of first optical fibers 112 arranged side by side, and the second optical fiber group 120 includes a plurality of second optical fibers 122 arranged side by side. In some embodiments, the first optical fiber group 110 is a four-core optical fiber, that is, the first optical fiber group 110 has four first optical fibers 112 arranged side by side. In some embodiments, the second optical fiber group 120 is a four-core optical fiber, that is, the second optical fiber group 120 has four second optical fibers 122 arranged side by side. In some embodiments, the first optical fiber group 110 and the second optical fiber group 120 may also be two-core optical fibers, six-core optical fibers, eight-core optical fibers, ten-core optical fibers, or twelve-core optical fibers, respectively.

In some embodiments, a portion of the plurality of adjacently arranged first optical fibers 112 is fixed by the first colloid 150, and a portion of the plurality of adjacently arranged second optical fibers 122 is fixed by the second colloid 160. In some embodiments, the plurality of first optical fibers 112 are coplanar with each other at the first end T1 of the first optical fiber group 110. In some embodiments, the plurality of first optical fibers 112 are coplanar with each other at the second end T2 of the first optical fiber group 110. In some embodiments, the plurality of second optical fibers 122 are coplanar with each other at the third end T3 of the second optical fiber group 120. In some embodiments, the plurality of second optical fibers 122 are coplanar with each other at the fourth end T4 of the second optical fiber group 120.

In some embodiments, the first colloid 150 and the second colloid 160 may be adhesives in the form of solid, liquid, or gel of solvent type, thermosetting type, or UV type. In some embodiments, the first colloid 150 and the second colloid 160 may be adhesives whose viscosity is changed by, for example, irradiation with light or heating. In some embodiments, the first colloid 150 and the second colloid 160 may be the same or different colloids, and may be adhesives with different viscosities according to the degree of bending of the optical fiber. In some embodiments, the plurality of first optical fibers 112 fixed by the first colloid 150 form the first optical fiber group 110, and the plurality of first optical fibers 122 fixed by the second colloid 160 form the second optical fiber group 120. In some embodiments, the first colloid 150 fixes the first end T1 of the first optical fiber group 110, and the second colloid 160 fixes the third end T3 of the second optical fiber group 120. In some embodiments, the first colloid 150 fixes the second end T2 of the first optical fiber group 110, and the second colloid 160 fixes the fourth end T4 of the second optical fiber group 120.

Referring to FIG6 , FIG6 is a schematic diagram of the lengths of the plurality of first optical fibers 112 and the plurality of second optical fibers 122 drawn in some embodiments of FIG4 . In some embodiments, the lengths of each of the plurality of first optical fibers 112 are different, and the lengths of each of the plurality of second optical fibers 122 are different. In some other embodiments, the lengths of each of the plurality of first optical fibers 112 may be the same, and the lengths of each of the plurality of second optical fibers 122 may be the same. In some embodiments, the length of each of the plurality of second optical fibers 122 is greater than the length of each of the plurality of first optical fibers 112.

FIG7 is a flow chart of an optical device assembly method according to some embodiments of the present disclosure. Referring to FIG7 , the optical device assembly method 200 includes steps 101, 103, 105, 107, 109, 111, 113, and 115. FIG8 to FIG21 are schematic diagrams of operation steps of the optical device assembly method of FIG7 according to some embodiments of the present disclosure.

Referring to FIG8 , in step 101 of FIG7 , a first substrate 180 is provided. In some embodiments, the first substrate 180 includes, but is not limited to, a glass substrate, a ceramic substrate, a metal substrate, or a semiconductor substrate. In some embodiments, the first substrate 180 has a first groove 182 and a second groove 184. In some embodiments, the first groove 182 and the second groove 184 may be grooves with a specific width and depth formed on the first substrate 180 using a laser drilling or etching process. In some embodiments, the first groove 182 and the second groove 184 have the same depth. In some embodiments, the first groove 182 has a first endpoint E1 and a second endpoint E2 relative to the first endpoint E1, and the second groove 184 has a third endpoint E3 and a fourth endpoint E4 relative to the third endpoint E3. In some embodiments, the first groove 182 and the second groove 184 are not substantially linear grooves.

In some embodiments, the length of the first groove 182 is different from the length of the second groove 184. In some embodiments, the distance between the first endpoint E1 of the first groove 182 and the third endpoint E3 of the second groove 184 is greater than the distance between the second endpoint E2 of the first groove 182 and the fourth endpoint E4 of the second groove 184. In some embodiments, the first groove 182 has a first arcuate edge S1, and the second groove has a second arcuate edge S2. In some embodiments, the first arcuate edge S1 and the second arcuate edge S2 are not parallel. In some embodiments, the distance L1 between the first arcuate edge S1 and the second arcuate edge S2 may vary along the length direction of the first groove 182 or the second groove 184. Taking FIG. 8 as an example, the distance L1 may gradually increase from the second endpoint E2 toward the first endpoint E1. In other embodiments, the distance L1 may gradually decrease from the second endpoint E2 toward the first endpoint E1.

Referring to Fig. 9, Fig. 9 is a cross-sectional view drawn according to some embodiments of Fig. 8. In some embodiments, the first groove 182 has a first width W1, and the second groove 184 has a second width W2. In some embodiments, the first width W1 is predefined according to the number of first optical fibers 112 to be placed, and the second width W2 is predefined according to the number of second optical fibers 122 to be placed.

Referring to FIG. 10 , FIG. 10 is a schematic diagram of the first substrate 180 in FIG. 8 according to some other embodiments. In some embodiments, the first substrate 180 may have a protrusion 180P and an extrusion portion 180S. In some embodiments, the protrusion 180P and the extrusion portion 180S are two blocks formed by dividing the first substrate 180 using a laser drilling or etching process. In some other embodiments, the extrusion portion 180S may be a material different from the first substrate 180 or the protrusion 180P. In some embodiments, the extrusion portion 180S and the protrusion 180P may be separated to form a first groove 182 and a second groove 184. In some embodiments, the first groove 182 and the second groove 184 are substantially semi-open grooves.

Referring to FIG. 11 , FIG. 11 is a cross-sectional view drawn according to some embodiments of FIG. 10 . In some embodiments, at least one side F1 of the protrusion 180P is parallel to at least one side F2 of the extrusion portion 180S. In some embodiments, the first width W1 of the first groove 182 and the second width W2 of the second groove 184 are adjustable. In such embodiments, the extrusion portion 180S can be slid in a direction Z1 toward the first groove 182 or the second groove 184 to adjust the size of the first width W1 or the second width W2. In some embodiments, the extrusion portion 180S can be slid in a direction Z1 to bring the extrusion portion 180S and the protrusion 180P closer together.

12 , in step 103 of FIG7 , a plurality of first optical fibers 112 and a plurality of second optical fibers 122 are placed in the first groove 182 and the second groove 184 on the first substrate 180. In some embodiments, a single first optical fiber 112 and a single second optical fiber 122 have sufficient elasticity and can be placed in the first groove 182 and the second groove 184 along the first arc-shaped edge S1 of the first groove 182 and the second arc-shaped edge S2 of the second groove 184, respectively.

13, after completing step 103, the first groove 182 and the second groove 184 are respectively filled with the plurality of first optical fibers 112 and the plurality of second optical fibers 122. In some embodiments, after placing the plurality of first optical fibers 112 in the first groove 182 and the plurality of second optical fibers 122 in the second groove 184, the plurality of first optical fibers 112 are adjacent to each other side by side, and the plurality of second optical fibers 122 are adjacent to each other side by side. In some embodiments, the first arcuate edge S1 and the second arcuate edge S2 respectively limit the extension direction of the plurality of first optical fibers 112 and the plurality of second optical fibers 122.

Referring to Fig. 14, Fig. 14 is a cross-sectional view drawn according to some embodiments of Fig. 13. In some embodiments, the plurality of first optical fibers 112 are packed in the first groove 182 in a coplanar manner, and the plurality of second optical fibers 122 are packed in the second groove 184 in a coplanar manner. In some embodiments, the first groove 182 restricts the movement of the plurality of first optical fibers 112 in the width W1 direction, and the second groove 184 restricts the movement of the plurality of second optical fibers 122 in the width W2 direction.

Referring to FIG. 15 , FIG. 15 is a schematic diagram of the operation of using the first substrate 180 in FIG. 10 or FIG. 11 . In some embodiments, after placing the plurality of first optical fibers 112 in the first groove 182 and the plurality of second optical fibers 122 in the second groove 184, respectively, the second substrate 190 may be placed on the first substrate 180. In some embodiments, the second substrate 190 may be a substrate made of the same material as the first substrate 180. In some embodiments, the second substrate 190 covers the plurality of first optical fibers 112, the plurality of second optical fibers 122, the extrusion portion 180S, and the protrusion 180P. In some embodiments, the second substrate 190 may prevent the plurality of first optical fibers 112 from being separated from the first groove 182 or the plurality of second optical fibers 122 from being separated from the second groove 184, so that the plurality of first optical fibers 112 are arranged in a coplanar manner in the first groove 182, and the plurality of second optical fibers 122 are arranged in a coplanar manner in the second groove 184. In some embodiments, the second substrate 190 presses the plurality of first optical fibers 112 in the first groove 182 and the plurality of second optical fibers 122 in the second groove 184. In some embodiments, the pressing portion 180S may be forced mechanically or manually to press one side of the plurality of first optical fibers 112 or one side of the plurality of second optical fibers 122.

In some embodiments, after the two ends of the plurality of first optical fibers 112 are squeezed by the squeezing portion 180S and the protruding portion 180P, the squeezed plurality of first optical fibers 112 are adjacent to each other and arranged side by side in the first groove 182. After the two ends of the plurality of second optical fibers 122 are squeezed by the squeezing portion 180S and the protruding portion 180P, the squeezed plurality of second optical fibers 122 are adjacent to each other and arranged side by side in the second groove 184. In some embodiments, the squeezing portion 180S and the protruding portion 180P restrict the movement of the plurality of first optical fibers 112 in the width W1 direction and the movement of the plurality of second optical fibers 122 in the width W2 direction. In some embodiments, after the squeezing and shaping of the plurality of first optical fibers 112 and the plurality of second optical fibers 122 are completed, the second substrate 190 is removed.

Referring to FIG. 16 , in step 105 of FIG. 7 , the plurality of first optical fibers 112 and the plurality of second optical fibers 122 are fixed by fixing devices, respectively. In some embodiments, the first and second fixing devices J1 and J2 are used to fix both ends of the plurality of first optical fibers 112, and the third and fourth fixing devices J3 and J4 are used to fix both ends of the plurality of second optical fibers 122, respectively. In some embodiments, the first to fourth fixing devices J1 to J4 may be a clamp or a sieve, but are not limited thereto. In some embodiments, the first and second fixing devices J1 and J2 may be moved along the length direction of the plurality of first optical fibers 112 to change the fixed position. In some embodiments, the third and fourth fixing devices J3 and J4 may be moved along the length direction of the plurality of second optical fibers 122 to change the fixed position.

Referring to FIG. 17 , in step 107 of FIG. 7 , the second substrate 190 is covered on the first substrate 180. In some embodiments, the second substrate 190 contacts each of the plurality of first optical fibers 112 in the first groove 182 and each of the plurality of second optical fibers 122 in the second groove 184. In some embodiments, the second substrate 190 presses against the plurality of first optical fibers 112 in the first groove 182 and the plurality of second optical fibers 122 in the second groove 184. In some embodiments, the plurality of first optical fibers 112 and the plurality of second optical fibers 122 are kept substantially coplanar with each other before preforming by limiting the space sandwiched between the second substrate 190 and the first substrate 180.

Referring to FIG. 18, in step 109 of FIG. 7, preforming of a plurality of first optical fibers 112 and a plurality of second optical fibers 122 is performed. In some embodiments, the second substrate 190 can be removed to apply the first colloid 150 and the second colloid 160 to the plurality of first optical fibers 112 and the plurality of second optical fibers 122, respectively. In some embodiments, the first colloid 150 and the second colloid 160 can be adhesives in the form of solid, liquid, or colloid of solvent-based, thermosetting, or UV-based. In some embodiments, the first colloid 150 and the second colloid 160 can be adhesives whose viscosity is enhanced by, for example, irradiation or heating. In some other embodiments, the first colloid 150 and the second colloid 160 can be adhesives that can be cured quickly without irradiation or heating. In some embodiments, the first colloid 150 and the second colloid 160 can be quick-drying adhesives, for example, quick-drying glues that are completely cured within 30 seconds. In some embodiments, the first colloid 150 and the second colloid 160 can be the same or different colloids. In some embodiments, after the first colloid 150 and the second colloid 160 are cured, the plurality of first optical fibers 112 are closely attached to each other, and the plurality of first optical fibers 122 are closely attached to each other. In some embodiments, after the first colloid 150 and the second colloid 160 are completely cured, the plurality of first optical fibers 112 are adhered to form the first optical fiber group 110, and the plurality of second optical fibers 122 are adhered to form the second optical fiber group 120.

Referring to FIG19, in step 111 of FIG7, the first optical fiber group 110 and the second optical fiber group 120 are removed from the first substrate 180. In some embodiments, the first optical fiber group 110 and the second optical fiber group 120 after removal have a bending direction shaped according to the first arc-shaped edge S1 of the first groove 182 and the second arc-shaped edge S2 of the second groove 184 as shown in FIG8. In some other embodiments, the first optical fiber group 110 may not be removed from the first groove 182 or the second optical fiber group 120 may not be removed from the second groove 184 temporarily, and the first optical fiber group 110 and the second optical fiber group 120 may be removed from the first substrate 180 after completing the subsequent steps.

Referring to FIG. 20 , in step 113 of FIG. 7 , a portion of the first optical fiber group 110 and a portion of the second optical fiber group 120 are cut respectively. In some embodiments, after the preforming step is completed, the first to fourth fixtures J1 to J4 may be temporarily removed. In some embodiments, the first end T1 of the first optical fiber group 110 is combined with the optical signal receiving end 132, and the third end T3 of the second optical fiber group 120 is combined with the optical signal emitting end 134. In some embodiments, the second end T2 of the first optical fiber group 110 is passed through the optical fiber connector 140 through the first connector 142, and the fourth end T4 of the second optical fiber group 120 is passed through the optical fiber connector 140 through the second connector 144. In some embodiments, a portion of the first optical fiber group 110 protruding from the optical signal receiving end 132 and a portion of the second optical fiber group 120 protruding from the optical signal emitting end 134 are cut along the cutting direction C1 using a cutting tool or a laser light source (not shown). In some embodiments, a cutting tool or a laser light source is used to cut a portion of the first optical fiber group 110 protruding from the optical fiber connector 140 and a portion of the second optical fiber group 120 protruding from the optical fiber connector 140 along the cutting direction C2. In other embodiments, the cutting can also be performed when the first optical fiber group 110 and the second optical fiber group 120 have not yet been removed from the first substrate 180.

Referring to FIG. 21 , in step 115 of FIG. 7 , the optical device P1 is assembled. In some embodiments, the optical signal receiving end 132 and the optical signal emitting end 134 are coupled to the optical receiving transmitter 130, respectively, to complete the assembly of the optical device P1. In some embodiments, the optical signal receiving end 132 is coupled to the optical signal inlet of the optical receiving transmitter 130, and the optical signal emitting end 134 is coupled to the optical signal outlet of the optical receiving transmitter 130. In some other embodiments, the optical device P1 may be assembled with the first optical fiber group 110 and the second optical fiber group 120 on the first substrate 180. In such an embodiment, after the assembly of the optical device P1 is completed, the first optical fiber group 110 and the second optical fiber group 120 may be taken out from the first groove 182 and the second groove 184, respectively.

The present disclosure provides a method for pre-shaping a plurality of optical fibers before assembling an optical device. A plurality of optical fibers are arranged by using a jig having a predefined shape, and then the plurality of optical fibers are bonded through a pre-shaping step to form an optical fiber group having the predefined shape. The plurality of optical fiber groups may have optical signal transmitting or receiving ends required to cooperate with the optical receiving transmitter. Therefore, the optical fiber group can be easily combined with the optical signal transmitting or receiving end required by the optical receiving transmitter, further reducing the stress effect at the coupling interface between the optical receiving transmitter and the corresponding optical signal transmitting or receiving end, improving the problem of excessive stress when the optical signal transmitting end or receiving end of the unshaped optical fiber group is coupled with the optical receiving transmitter, and thus improving the reliability of the optical device.

Although the present disclosure and its advantages have been described in detail, it should be understood that various changes, substitutions and replacements may be made without departing from the spirit and scope of the present disclosure as defined in the claims. Furthermore, the scope of the present application is not limited to the specific embodiments of the processes, machines, manufactures, material compositions, means, methods and steps described in the specification. A person skilled in the art can understand from the disclosure of the present disclosure that existing or future developed processes, machines, manufactures, material compositions, means, methods, or steps that have the same functions or achieve substantially the same results as the corresponding embodiments described herein can be used according to the present disclosure. Accordingly, such processes, machines, manufactures, material compositions, means, methods, or steps are included in the claims of the present application.

Claims (17)

1. A method of forming an optical device, comprising:

providing a first substrate, wherein the first substrate is provided with a first groove and a second groove, the first groove comprises a first end point and a second end point corresponding to the first end point, and the second groove comprises a third end point and a fourth end point corresponding to the third end point;

Respectively placing a plurality of first optical fibers in the first groove and a plurality of second optical fibers in the second groove;

Covering a second substrate on the first substrate; and

Performing a preforming step to adhere the first optical fibers to form a first optical fiber group and adhere the second optical fibers to form a second optical fiber group, wherein the first optical fiber group has a first end and a second end opposite to the first end, and the second optical fiber group has a third end and a fourth end opposite to the third end,

The lengths of each of the plurality of second optical fibers are equal, the lengths of each of the plurality of first optical fibers are different, and a distance between the first optical fiber group and the second optical fiber group is gradually increased from the second end portion or the fourth end portion towards the first end portion or the third end portion.

2. The method of claim 1, wherein the plurality of first optical fibers are disposed adjacent side-by-side and the plurality of second optical fibers are disposed adjacent side-by-side after the placing of the plurality of first optical fibers in the first groove and the placing of the plurality of second optical fibers in the second groove, respectively.

3. The method of claim 1, wherein the first groove limits lateral movement of the first plurality of optical fibers and the second groove limits lateral movement of the second plurality of optical fibers.

4. The method of claim 1, wherein the first groove has a first arcuate edge and the second groove has a second arcuate edge, the first arcuate edge and the second arcuate edge defining the directions of extension of the plurality of first optical fibers and the plurality of second optical fibers, respectively.

5. The method of claim 4, wherein a distance between the first arcuate edge and the second arcuate edge varies along a length of the first groove or the second groove.

6. The method of claim 4, wherein after the covering the second substrate on the first substrate, the second substrate presses against the plurality of first optical fibers in the first trench and the plurality of second optical fibers in the second trench so that the plurality of first optical fibers and the plurality of second optical fibers are coplanar with each other.

7. The method of claim 4, further comprising: a first fixing device and a second fixing device are arranged to fix two ends of the first optical fibers respectively, and a third fixing device and a fourth fixing device are arranged to fix two ends of the second optical fibers respectively.

8. The method of claim 4, wherein the preforming step comprises: and coating an adhesive on the first optical fibers and the second optical fibers, and forming a first colloid and a second colloid respectively after the adhesive is cured.

9. The method of claim 4, wherein the second substrate and the first substrate are removed after the preforming step.

10. The method of claim 4, further comprising: cutting a portion of the first optical fiber set, and cutting a portion of the second optical fiber set.

11. An optical device formed by the method of any one of claims 1-10, comprising:

a first optical fiber group having a first end and a second end opposite to the first end, and including a plurality of first optical fibers arranged side by side with each other; and

A second optical fiber group having a third end and a fourth end opposite to the third end, and comprising a plurality of second optical fibers arranged side by side with each other, wherein a length of each of the plurality of second optical fibers is greater than a length of each of the plurality of first optical fibers.

12. The optical device of claim 11, wherein a portion of the first plurality of optical fibers are coplanar with one another and a portion of the second plurality of optical fibers are coplanar with one another.

13. The optical device of claim 11, further comprising:

a first glue body for fixing a part of the first optical fiber group; and

And a second glue body for fixing a part of the second optical fiber group.

14. The optical device of claim 11, further comprising:

an optical receiving transmitter is coupled to the optical signal receiving end and the optical signal transmitting end, wherein the optical signal receiving end comprises a first end portion, and the optical signal transmitting end comprises a third end portion.

15. The optical device of claim 14, wherein the optical receiving transmitter comprises an optical waveguide to receive optical signals from the first set of optical fibers or to transmit optical signals to the second set of optical fibers.

16. An optical device formed by the method of any one of claims 1-10, comprising:

a first optical fiber group having a first end and a second end opposite to the first end, and including a plurality of first optical fibers arranged side by side with each other; and

The second optical fiber group is provided with a third end part and a fourth end part opposite to the third end part, and comprises a plurality of second optical fibers which are arranged side by side, wherein the distance between the first optical fiber group and the second optical fiber group is changed along the length direction of the first optical fiber group or the second optical fiber group.

17. The optical device of claim 16, wherein the second optical fiber set has an included angle greater than 0 degrees with respect to the first optical fiber set.