MXPA97004977A - Optico microrreplic module - Google Patents

Abstract

An optical modfor interconnecting two or more optical fibers having a microreplicated waveguide element which is integrally formed on the same substrate with a splice element is described. In one embodiment, the modhas three plates, a lower plate, a cover plate and an upper plate, all contained within a common housing, The lower plate has grooves that receive the fiber and fiber alignment slots in its At the ends, the fiber alignment slots are aligned with the waveguide channels formed on the central portion of the bottom plate. The cover plate is used when the cores of the waveguide channels are formed, to force the curable, residual waveguide material into the flow channels adjacent to the waveguide channels and this material, when it cures or solidifies, adheres to the bottom and deck plates together. The upper plate is used to hold the fibers which are retained in the alignment slots of the fiber, with the center of the fibers aligned with the core of the waveguide channels. The housing of the modincludes wedges which can be independently operated to secure the fibers in a reachable way either to one end or the other of the mod

Description

BACKGROUND OF THE INVENTION Field of the invention The present invention relates in general to devices for operatively connecting the ends of waveguides such as optical fibers and more particularly to an article which interconnects at least an optical fiber to at least one other optical fiber and has a flat, microreplicated structure, with optical waveguides formed therein.

Description of the prior art With the widespread commercialization of fiber optic networks, it has become important to provide optical interconnection devices which are not only easy to use and reliable, but can also be manufactured in a non-expensive manner and in massive amounts. Optical splitters are of particular interest since they allow a single fiber (input) to be interconnected with a plurality of fibers (output) or allow the optical serial of multiple input fibers to merge into a single waveguide. Dividers can play an important role in the use of optical fibers for telecommunications, cable television and data transmission. Optical splitters are commonly manufactured by fusing optical fibers or by permanently joining the fibers to an integrated optical device REP: 24929 glass, flat, which guides the light from the input fibers to the output fibers (spiral connection or flexible connection). The spiral connection (or flexible connection) is a critical step in the manufacture of the integrated flat glass optical devices since the cost of the device is proportional to the number of fiber junctions desired. The spiral connection stage includes the alignment of the fiber optic waveguide paths with the diffuse ion paths or channel waveguides in the splitter and the joining of the flexible ends of the fiber at the end face of the fiber. component. The alignment must be very precise and the joint must ensure the stability of the alignment during environmental variations. Precise alignment is often difficult, especially for single-mode waveguides whose core diameters are of the order of 8 microns. This spiraling process of intense labor prevents flat integrated optical devices from being produced massively with economy. To reduce the cost of actively aligning the optical fibers to an optical waveguide or coupler device, it is known that the optical fibers can be first inserted and permanently attached to a fiber alignment substrate which subsequently aligns and permanently bonds. to the optical waveguide substrate. The economy results from the alignment of a plurality of optical fibers in one stage. This method of bonding the fiber requires permanent bonding of the fibers to the optical waveguide device and further requires polishing the substrate that aligns the fiber and the optical waveguide substrate before they are joined together. See U.S. Patent No. 5,197,109. A process for producing optical polymeric components with an integrated fiber-chip coupling mechanism is described in the patent application under the Patent Cooperation Treaty No. WO 93/21550. This application teaches a process for manufacturing integrated optical components by molding polymeric materials. The fiber guide slots are molded in precise correspondence with the waveguides of the integrated optical channel to provide the passive alignment of * p + 38X the flexible or coiled connections of the optical fiber to the channel waveguide device. The application further describes a method wherein the ends of the glass fiber are placed in positioning slots in the molded polymeric components and the orifices are filled with a polymerizable monomer. With a cover plate applied, the material is polymerized in situ. The application fails to describe a method for rapidly or reliably splicing or connecting a plurality of fibers to the microreplicated waveguide device and does not teach any kind of housing that encloses or supports the microreplicated device. A similar method for the production of optically integrated waveguides with fiber guide structures and the use of the molding of polymeric materials is shown in US patent No. .311, 604. That invention is related to the simultaneous production of optically integrated waveguides and micro-mechanical components for fiber guidance. An optical substrate contains at least one polymeric waveguide structure, transferred in the form of recesses by molding a polymeric substrate. The recesses are filled with a material having a refractive index higher than the substrate. An optical substrate containing at least one waveguide structure with at least one fiber guide structure in polymers is also described. The bonding of the fiber is obtained by the same mechanism used in WO 93/21550, wherein the ends of the optical fiber are placed in positioning grooves in the molded polymeric components. Further described is a method for coupling the fibers to the optically integrated waveguide by inserting the fibers into the fiber guide recesses; A cover plate is attached, which extends over the recesses that guide the fiber. Means are not shown for providing a low retroreflection, low loss connection between the optical fibers and the channel waveguides, nor means for retaining the optical fibers in a precise fixed orientation with respect to the waveguides of the Chanel. In another aspect of that invention, the fibers are inserted into the guide grooves and the orifices are filled with a polymerizable monomer, with a cover plate applied, the material is polymerized again in situ. The method of bonding the fiber is again permanent and requires a clean room environment to eliminate the possibility of contamination of the waveguide channels during the application of the polymerizable material of high refractive index. So the installation in the field is quite difficult if not impossible. The '604 patent also fails to show a method for quickly or reliably splicing or connecting a plurality of fibers to the microreplicated waveguide device in a re-engageable manner and neither does the application teach a housing that encloses or supports the device. European Patent Application 560,043 discloses a method for producing flat waveguide elements for fiber optic networks and components according to this method. The application claims a method for producing integrated, passive optical components, from polymeric materials, consisting of at least one molded part with channels for optical waveguides and fiber guide grooves and at least an optical waveguide similar to fiber, coupled. The optical fibers can be attached to the integrated waveguide by inserting the fibers into the fiber guides, the cover plate extends over the recesses for the fiber guides and the fibers and the pressing of the fibers into the holes or recesses. No means is provided to provide a low retroreflection, low loss connection between the optical fibers and the channel waveguides, nor is any means discussed for retaining the optical fibers in a precise fixed orientation with respect to the guides channel wave. This patent discusses another method for inserting the optical fibers into the fiber guides, whereby the fibers are fixed in their position by the polymerizable material that is filled to the channels of the waveguide. This technique suffers from the same difficulties inherent in the device of the '604 patent with respect to installation in the field. The European application again fails to show a method for quickly or reliably connecting or splicing a plurality of fibers to the microreplicated waveguide device in a re-engageable manner or a housing that encloses or supports the device. German patent application 4,217,553 teaches a method for spirally connecting optical fibers to an integrated microreplicated optical component in polymeric materials. The polymeric waveguide element incorporates V-shaped slots for fiber alignment, molded in precise correspondence with the channels of the waveguide. The fibers to be joined are fastened in an assembly with the ends of the fibers protruding from an end surface. This assembly assembly with protruding fiber ends is placed over the V-shaped slots of fiber alignment in the waveguide element and then lowered into the V-shaped slots, pressed and fixed to the correct position. A polymerizable monomer is applied to the channels of the molded waveguide, which flows on contact with the optical fibers and polymerizes, to simultaneously form the centers or cores of the channel waveguide and to polymerize the fibers in place. This method of bonding the fibers is permanent and requires a clean room environment to eliminate the possibility of contamination of the waveguide channels during the application of the polymerizable material of high refractive index.; this again makes the installation in the field practically impossible. Additionally, the method of inserting the fiber via the assembly requires that all fibers be cut to a precise length with a tolerance of less than 10 microns. The '553 application does not teach a method for reattach- able attachment of the optical fibers, nor does it result in a low retroreflection connection, of low insertion loss of the fibers to the molded waveguide article. A portion of the fiber optic connector comprising a body of molded polymeric materials and at least one passive, discrete, integrated optical chip permanently encapsulated within the polymeric body material is described in U.S. Patent No. 5,276,755. This patent teaches the encapsulation of an integrated optical chip connected spirally in the polymer body of the connector. It does not teach a method for connecting or splicing the spiral or flexible connections of the fiber to the integrated optical chip itself, nor does it teach a spliced or connected article which allows a splice connection or reattachable directly to the chip, without the use of a spiral connection of fiber permanently attached. The '755 patent does not further teach a method or article for obtaining a low retroreflective, low loss optical connection between the optical fibers and the molded channel waveguides.

A molded waveguide splitter is shown in U.S. Patent No. 5,265,184 having slots that provide alignment of a fiber ribbon connector to a molded waveguide device. This reference also fails to teach means for providing a low retroreflection, low loss connection between the optical fibers and the channel waveguides, or no means for retaining the optical fibers in precise fixed orientation with respect to the waveguides of the Chanel. The precision with which the connector is aligned to the molded waveguide device is determined by the accuracy with which the alignment features are molded onto the waveguide device and the fiber ribbon connector. In addition, the relative spacings of the individual fibers in the ribbon determine the accuracy with which the optical connections between the fibers and the channel waveguides are made. The '184 patent teaches no means to align the optical fibers to the channel waveguides with submicroscopic accuracy (required for single-mode applications) or teaches the molding of V-shaped slots of fiber alignment or channels of Fiber entry in precise alignment with molded waveguide channels. There is a lack of a description of a housing for the connector. It would therefore be desirable and advantageous to devise an integrated optical waveguide element with high performance multifiber splices or connectors for installation in the field of re-attachable multiple optical fibers to an integrated optical device. Such a device would eliminate the need to spirally connect the optical waveguide device prior to installation in the field, to effectively reduce the likelihood of damage to the fiber and to keep the handling of the fiber to a minimum. The integration of a high performance multifiber splice or connector on the microreplicated waveguide device would also allow the easy and inexpensive replacement or upgrade of the waveguide device.

BRIEF DESCRIPTION OF THE INVENTION The present invention provides an optical module comprising generally an optical waveguide element integrated on a common substrate with one or more fiber optic connectors or connectors. The optical module can be adapted to provide a plurality of different functions, which include but are not limited to a nxmo branch Y-coupler divider, a star coupler, a wavelength division multiplexer, an attenuator, a optical filter, a phase modulator and an optical derivation. The preferred embodiment of the optical module has an integrally microreplicated optical waveguide element with fiber alignment slots and fiber receiving channels, formed by using polymer, halogenated polymer, polymer / ceramic composite or ceramic materials in the which include transparent optical quality glasses and silicon. The module is provided with a body or housing that surrounds the waveguide element. In the nxm coupler embodiment of the present invention, the element has n grooves receiving the fiber and n fiber alignment slots, n waveguide channels which divide or converge to m waveguide channels and m alignment slots of the fiber and m slots that receive the fiber, where n and m are, independently, integers from 1 to 1, 024 inclusive, the n fiber alignment slots and m fiber alignment slots are adjusted in such a way that the cores of the optical fibers retained therein are properly aligned with the ends of the corresponding waveguide channels. In one embodiment, the molded splice body surrounding the waveguide element consists of a liner portion and a cap portion which are interlocked to retain the waveguide element. The waveguide element consists of three generally flat plates, a lower plate having grooves that receive the fiber in line with the fiber alignment slots and the corresponding waveguide channels, a cover plate and an upper plate with a recess for the cover plate. The lower and roof plates are joined together by means of the application of a polymerizable material which simultaneously forms the corrugations of the channel waveguide and adheres together to the upper and roof plates. By means of the precise filling of the waveguide channels with this polymerizable material, which is preferably of a refractive index greater than that of the waveguide element plates, an optical conduction is provided through the channels of the waveguide. The waveguide element is mounted, with the upper plate loosely fitted on the bottom / cover assembly prior to the insertion of the fiber and the drive by a wedge mechanism. The fibers which are stripped and split are inserted into the fiber insertion grooves, travel to the fiber alignment slots and stop as they are forcefully driven against the channels of the waveguide. The wedge mechanism is driven to urge the lower and upper plates to hold the fibers in alignment with the channel waveguides. The clamping force is preferably applied mainly to the fiber / channel interface. This results in a low insertion loss connection by means of the precisely molded fiber slots and the waveguide channels. A mechanical connection of low return loss of the fibers to the channel waveguides is obtained by virtue of the close coincidence of the refractive indices of the optical fiber materials and the materials used in the optical waveguide element microreplicated In addition, a low retroreflection is obtained by means of one or more of the following mechanisms: (i) the molding of an angular interface in the fiber-channel connection; (ii) the intimate contact of the optical fibers with the microreplicated waveguide channels, so that no air interface is formed; or (iii) application of a corresponding refractive index material in the fiber-channel connection. The angular interface is preferably used with either of the other two mechanisms to obtain retroreflections from -50 to -60 dB. A stacked waveguide element can be provided in the splice body, which has more than the lower, roof and top plates, for example, a stack of plates accommodating two layers of waveguide elements. The special guides positioned at each end of the plates can be used to direct some of the fibers upward to one layer of the waveguide and others down to the other layer. The end covers are provided to protect the waveguide element and the exposed fibers and to provide an environmental seal.

BRIEF DESCRIPTION OF THE DRAWINGS The invention will be better understood by reference to the accompanying drawings in which: Figure 1 is an exploded perspective view of an embodiment of the microreplicated optical module of the present invention, showing a microreplicated waveguide element; integrally with a wedge-driven fiber optic splice; Figure 2 is a perspective view of a waveguide element used in accordance with the present invention, in its unassembled state, incorporating a 2x4 waveguide splitter; Figure 3 is a perspective view of an alternative embodiment of the waveguide element of the present invention, incorporating multiple optical devices in a single element; Figure 4 is a perspective view of the groove detail of the fiber waveguide channel of the waveguide element of Figure 2; Figure 5 is a perspective view of another alternative embodiment of a waveguide element used in the optical module of the present invention, also shown in an unmounted state; Figure 6 is a perspective view of the waveguide element of Figure 5, shown in section and in its non-assembled state; Figure 7 is a perspective view of yet another embodiment of the waveguide element of the present invention, with fiber insertion and alignment slots that are molded into the upper and lower plates; and Figure 8 is a perspective view of the slot detail of the fiber waveguide channel of the bottom plate of the waveguide element of Figure 7.

DESCRIPTION OF THE PREFERRED EMBODIMENT With reference now to the figures and in particular with reference to Figure 1, a mode 10 of the optical coupler of the present invention is shown. The coupler 10 generally consists of a housing, composed of a liner 12 and lids 14 and an integrated splice / waveguide element 16. The housing is similar to that shown in U.S. Patent No. 5,155,787 (incorporated herein) and each of its components is preferably constructed of a durable injection moldable polymer, such as the liquid crystal polymer sold by Celanese under the brand name VECTRA. The liner 12 has a longitudinal groove thereon, generally rectangular in cross section, to receive the element 16. However, the liner 12 is shorter than the element 16, so that the ends of the element 16 protrude at covers 14 when the coupler 10 is fully assembled. One side of the inner groove (below the liner 12 in figure 1 and not visible) has a hole or holes which accommodate two drive wedges 18. These wedges are held in place by lids 14 and when they move from a non-driven state to a driven state, they result in a clamping force exerted on the element 16. The tabs 20, which extend from the lids 14, are they interpose between the respective wedges and the element 16 to reduce the frictional coupling between the wedges and the splice / waveguide element. The liner 12 may have a reinforcing tube, molded into an insert, surrounding the groove which receives the element 16, as taught in U.S. Patent No. 5,309,538 (incorporated herein). The liner 12 and the lids 14 define many superimposed surfaces which impart additional environmental sealing and further inhibit the separation of these components caused by stresses such as bending of the housing. The covers 14 also have a groove for receiving a portion of the element 16 and further have areas 22 between ribs which compensate the distal ends of the element 16 and provide access to the fiber receiving grooves discussed below. The end covers 24 provide an environmental seal around the ends of the coupler. The end covers 24 can be hingedly joined along one side to the covers 14 and have hooks or other means for securing the covers in a closed position. A sealing material, such as a corresponding refractive index gei can be placed on the end covers 24, such that the sealant escapes and is directed towards the splice areas when the covers are moved to their closed position. As suggested by its name, the splice / waveguide element 16 includes features which make it act as a splice element and as a waveguide element and yet these features are integrated into a common substrate. In the coupler 10, it can be said that there are two splices, one at each end thereof, while the central portion of the element 16 constitutes a waveguide element. The term "splice" is often used to refer to the permanent interconnection of two optical waveguides, as opposed to a "connector" which provides a re-engagable interconnection. As used herein, however, the term "splice" should not be interpreted in a limiting sense; certainly, the preferred embodiment contemplates splice means at each end of the coupler which allow the re-engageable connection of the fibers. Similarly, the term "coupler" is sometimes used for a specific type of connector which has at least one Y-shaped branch, but as used herein refers more generally to any device which provides some amount of optical continuity between the ends of at least two optical fibers. The term "interconnection" means normal connections (straight-through), as well as other types of optical devices such as dividers, attenuators, etc. With reference to Figure 2, the splice / waveguide element 16, shown in a non-assembled state, is described in further detail. In one embodiment of the coupler 10, the element 16 comprises three plates 26, 28 and 30 (preferably flat and rectangular). The bottom plate 26 has two splice areas, one at each end, with V-shaped grooves, for fiber alignment, formed therein and a central portion having a waveguide element including the channels 34 of Waveguide. The lower plate 26 has extensions or gate areas 36 with grooves 38 receiving the fiber, V-shaped, formed therein. The fibers that are inserted into the splice usually have an intermediate or buffer coating which is removed or removed from the terminal ends of the fiber, that is, that portion of the fibers which falls into the fiber alignment slots 32. Therefore the slots 38 receiving the fiber have ramp portions 40 which accommodate the cushioned portion of the optical fibers to minimize the microfiection of the fibers at the transition from the cushioned portion thereof to the exposed portion thereof. and to help avoid the optical losses associated with such microfiexion. The slots 38 receiving the fiber are also wider than the fiber alignment slots 32 as they accommodate the cushioned portion of the fibers. Those skilled in the art will appreciate that the shape of the grooves 32 and 38 are not limited to the "V" shaped cross sections, but in the preferred embodiment the grooves are V-shaped and have an interior angle of approximately 60. °. In this way, when a fiber is placed in one of the slots and the element 16 is mounted to the module housing, the contact points between the plates 26 and 30 and the fiber generally form an equilateral triangle which minimizes the transverse displacement of fiber and thus also reduces the loss of the signal. The upper plate 28 has a recess 42 which accommodates the plate of cover when the plates are in the assembled state and the cover plate 30 is interposed between the inner plate 26 and the upper plate 30. The upper plate 28 can be partially secured to, and aligned with, the lower plate 26 by any convenient means, such as projections 44 formed on the upper plate 28 which engage the holes 46 formed on the lower plate 26. In this assembled position, one or more fibers inserted into the element 16 can be secured by sliding wedges 18, for result in a clamping force on the fibers due to the tapered configuration of the wedges. The wedges 18 are advantageously located adjacent the fiber alignment slots 32, such that they apply more clamping force near the channel interface of the waveguide / fiber than in the central portion of the element 16. Of course, the wedges 18 can be driven independently and thus the coupler 10 can initially be spliced on only one end, such as for the spiral connection and the other splice can be accomplished in the field. The lower plate 26 can be microreplicated from any durable material, preferably one which is sufficiently hard to avoid excess deformation of the grooves when the fibers are fastened therein, which include materials from the group consisting of of polymers, halogenated polymers, polymeric / ceramic or ceramic compounds, in which transparent glass of optical quality is included. Microreplication is carried out using methods which include injection molding, transfer molding, embossing or casting and curing. See, for example, U.S. Patent Nos. 5,311, 604 and 5,343,544. It is preferable to use a material such as halogenated polymers, since they usually exhibit lower optical losses. Similar materials can be used to fill the channels of the waveguide, that is, to form the waveguide cores. The upper plate 28 can be formed, but not necessarily, integrally with the lower plate 26 and joined thereto with a "focus" joint 48 as described in the '787 patent. The cover plate 30 can also be formed of the same material as the lower and upper plates 26 and 30. In the embodiment of figure 2, the waveguide element formed on the central portion of the plate 26 is a 2x4 splitter where the two input channels are divided in four output channels. More generally, the present invention contemplates a coupler of n x m where n and m are independently integers having a value between 1 and 1024 inclusive. Other configurations of n x m will become apparent to those skilled in the art, such as multiple couplers on I a single waveguide element. Similarly, different types of optical modules can be provided, such as a splitter, a star coupler, a wavelength division multiplexer, an attenuator, an optical filter, a phase modulator or an optical derivation and even combinations of these devices can be micro-replicated on a single waveguide element, side by side, end-to-end or in a variety of tree structures. For example, Figure 3 shows an alternative splice / waveguide element 16", where two 2 x 4 dividers are fabricated side by side on a single waveguide element, preferably the inlet and the inlet slots. are located on equal centers to facilitate the interconnection of a multiplicity of fibers in a single operation With reference now to the enlarged view of Figure 4, the cores of the optical fibers can be aligned precisely with the channels 34 of the waveguide by aligning channels over the centers of the V-shaped slots during microreplication For single-mode applications, the channels of the waveguide are approximately 8 microns wide and deep, with the V-shaped groove formed to align the optical axis of the fiber and the channel of the waveguide with an accuracy of the order of 0.5 microns . While the fiber / channel alignment slot interface is shown as a surface perpendicular to the axis of the fiber, it can be molded alternately at a slight angle of the perpendicular, ie 3 to 10 degrees, to reduce retroreflections in the interface less than -50 dB for the classic molded polymeric materials over a temperature range of -40 to + 75 ° C. A corresponding refractive index gel can optionally be used to further decrease insertion losses. Also shown in Figure 4 are flow channels 50 which can receive excess liquid monomer during the channel forming process as further explained below.

In Figures 2-4, all fiber insertion grooves, fiber alignment grooves and waveguide channels are molded onto the lower plate 26, the upper plate 28 incorporates recesses 42 for the cover plate 30. Figures 5 and 6 show another embodiment 16"of the splice / waveguide element of the present invention, wherein the fiber insertion slots 38 and the ramps 40 are molded onto the upper plate 28, with the slots 32 of fiber alignment and waveguide channels 34 still molded onto the bottom plate 26. The fibers inserted into the slots 38 are guided to the ramps 40 and to the alignment slots 32 where they align with the guide channels 40 A partial view of the mounted splice / waveguide member 16 is shown in Figure 6, which illustrates the relationship of the fiber insertion slots, the ramp and alignment slots of the fiber and the plates. lower, upper and roof. Still another embodiment 16"'of the splice / waveguide element of the present invention is shown in Figures 7 and 8. In the element 16'", the fiber alignment slots 32 are formed in the lower plate 26 and the upper plate 28 and are aligned by protrusions 44 and holes 46. Figure 8 reveals how, in this embodiment, the channels 34 of the waveguide are formed with an upper surface which is coplanar with the upper surface of the grooves 32. V-shaped. The channels 34 are preferably molded only in the lower plate 26, the fiber alignment slots are thus formed to center the axis of the fiber to the optical axis of the waveguide channels, this is, the V-shaped slots on the bottom 26 are only slightly deeper than those on the top plate 28. The channel / slot interface can be molded again at an angle to reduce retroreflections. The gel with corresponding refractive index can also be preloaded at the interface. The fibers whose terminal ends are beveled can be positioned against the channels 34 and exhibit acceptable losses without the gel, if a direct contact between the core of the fiber and the channel is obtained. All the above embodiments of the splice / waveguide element preferably use waveguide channels 34 which are formed by the polymerization of a monomer in situ. Following the molding of the splice element / waveguide using the desired material, inserts (not shown) are placed on the bottom plate 26, seated against the holes in the channels of the waveguide. These insert pieces are formed to fit into the slots 38 receiving the fiber and the fiber alignment slots 32. A liquid monomer, such as a fluorinated acrylate or other curable material is applied to the channels of the waveguide to form cores therein. The cover plate 30 is firmly placed on the lower plate 26, centered on the central portion thereof to form the waveguide element. As the cover plate 30 is pressed onto the lower plate 26, the residual monomer is expelled out of the waveguide channels and into the flow channels 50. This allows the channels to be filled to a precise depth without residual material forming a thin layer above the channel waveguides. The liquid monomer or other material cures or solidifies to form the cores of the waveguide channels and causes the plates 26 and 30 to adhere to each other. The inserts are removed from the slots that receive the fiber and from the fiber alignment slots. The upper plate 28 is placed (articulated) on top of the cover plate 30, the plate 30 engages the recess 42 and the projections 44 fit into the holes 46. Although the channels 34 of the waveguide shown are shown with the same width, different widths can be microreplicated on a single waveguide element. For example, Y-shaped branches which divide a single channel into two channels of different widths are known to provide an unequal division of the optical signal between the two output channels. In addition, the granules of the surface corrugation waveguide can also be microreplicated in the same waveguide element as the channel waveguides, to provide broadband and narrowband optical filtering which can effect multiplexing. of optical wavelength. Although the invention has been described with reference to specific embodiments, this description is not intended to be intertwined in a limiting sense. Various modifications of the described embodiment, also as alternative embodiments of the invention will be apparent to those skilled in the art upon a reference to the description of the invention. For example, protrusions of the fiber in the splice element / waveguide can be preloaded into the slots that receive the fiber, aligned with the waveguide cores and held in place by epoxy materials or other materials. curables, which include polymers and ceramics; then these fiber protrusions would be spliced to the input and output fibers. Accordingly, it is contemplated that such modifications may be made without departing from the spirit or scope of the present invention as defined in the appended claims.

It is noted that in relation to this date, the best method known by the applicant to carry out the present invention, is the conventional one for the manufacture of the objects to which it refers.

Having described the invention as above, property is claimed as contained in the following

Claims (24)

1. Claims 1. An article for interconnecting at least one optical fiber with at least one other optical fiber, characterized in that it comprises: an elongated substrate having first and second ends; an optical waveguide element formed integrally on the substrate, the waveguide element has at least one waveguide channel therein, filled with an optically transmitting material, the waveguide channel has first and second ends, wherein the optically transmitting material is filled to the at least one waveguide channel before interconnecting the optical fibers by the article; first splice means, integrally formed on the substrate, for receiving a first optical fiber at the first end of the substrate and aligning the first optical fiber with the first end of the channel of the waveguide; and second splice means integrally formed on the substrate, for receiving a second optical fiber at the second end of the substrate and aligning the second optical fiber with the second end of the waveguide channel.
2. 2. The article according to claim 1, characterized in that the waveguide element includes means adapted to provide one of a plurality of different functions selected from the group consisting of a coupler, a splitter, a star coupler, a multiplexer by division of wavelength, an attenuator, an optical filter, a phase modulator or an optical derivation.
3. 3. The article according to claim 1, characterized in that the first connecting means receive the first optical fiber in a reachable manner.
4. 4. The article according to claim 1, characterized in that the material that fills the channel of the waveguide is selected from the group consisting of polymers, halogenated polymers, polymer / ceramic or ceramic compounds.
5. 5. The article according to claim 1, characterized in that the waveguide element is formed from a material selected from the group consisting of polymers, halogenated polymers, polymer / ceramic or ceramic composites.
6. 6. The article according to claim 1, characterized in that it also comprises housing means surrounding the substrate, the waveguide element and the first and second splice means.
7. 7. The article according to claim 1, characterized in that the substrate comprises a first plate having first and second ends, at least one slot for aligning the fiber at each of the ends and a central portion with the at least one In the waveguide channel, the waveguide channel has first and second ends respectively aligned with the fiber alignment slots.
8. 8. The article according to claim 2, characterized in that: the first splice means include n fiber receiving slots formed in the first end of the substrate and n fiber alignment slots having first and second ends, the first ends of they are generally aligned with the n slots that receive the fiber respectively; the second splice means include fiber receiving slots formed in the following • end of the substrate and m fiber alignment slots having first and second ends, the first ends thereof being generally aligned with the slots that receive fiber respectively; and the waveguide element comprising a pixel coupler includes n waveguide channels which divide or converge to waveguide channels, the n waveguide channels are generally aligned with the second ends of the waveguides. fiber alignment slots respectively and the m waveguide channels are generally aligned with the second ends of the fiber alignment slots respectively, where n and m are independently, integers from 1 to 1, 024 inclusive .
9. 9. The article according to claim 4, characterized in that the material filling the channel of the waveguide is a transparent glass of optical quality.
10. 10. The article according to claim 5, characterized in that the material forming the element of the waveguide is a transparent glass of optical quality.
11. 11. The article according to claim 6, characterized in that the housing means include: a lining element; first and second lid elements attached to the lining element; and first and second end covers attached to the first and second cover elements respectively.
12. 12. The article according to claim 7, characterized in that it also comprises at least one projection of fiber located on the substrate, the fiber projection has first and second ends, the first end is aligned with the first end of the channel of the waveguide and the second end of the projection of the fiber is aligned with a respective slot of the fiber alignment slots.
13. 13. The article according to claim 7, characterized in that it further comprises: a second plate; and a third plate interposed between the first and second plates, the second plate has a recess to receive the third plate.
14. 14. The article according to claim 7, characterized in that: one of the alignment slots of the fiber has an alignment axis; and the first plate has a surface formed at an interface between the fiber groove and the waveguide channel, the surface is oriented at an angle which is not orthogonal to the alignment axis.
15. 15. The article according to claim 8, characterized in that: the channels of the waveguide define a top surface; and the slots receiving the fiber have a height which extends above the upper surface of the waveguide channels, such that a core of the waveguide channel is aligned with a center of its waveguide. respective slot that receives the fiber.
16. 16. The article according to claim 13, characterized in that it further comprises wedge means for actuating the first and second splicing means, the wedge means causing the second plate to be driven in a forced manner against the first plate when the wedge means is find in a powered state.
17. 17. The article according to claim 13, characterized in that the first and third plates are adhered to each other by a polymerizable material which also forms a core of the waveguide channel.
18. 18. The article according to claim 16, characterized in that: the alignment slots of the fiber and the channel of the waveguide define respective fiber / channel interfaces; and the wedge means applies more clamping force in the fiber / channel interfaces than in the central portion.
19. 19. An optical coupler for interconnecting optical fibers, characterized in that it comprises: an elongated substrate having first and second ends and a central portion; an optical waveguide element integrally formed on the central portion of the substrate, the waveguide element includes n waveguide channels which divide or converge on m waveguide channels, all channels are filled with an optically transmitting material wherein n and m are independently integers from 1 to 1, 024 inclusive, wherein the optically transmitting material is filled to the waveguide channels prior to the interconnection of the optical fibers by the optical coupler; first splice means, integrally formed on the substrate at the first end thereof, to receive at least a first optical fiber and align the first optical fiber with one of the n channels of the waveguide, the first splice means include n fiber receiving slots formed on the first end of the substrate and n fiber alignment slots having first and second ends, the first ends thereof being in general aligned with the n slots receiving the fiber respectively and second ends of the n fiber alignment slots are generally aligned with the n channels of the waveguide; second splice means, formed integrally on the substrate at the second end thereof, to receive at least a second optical fiber and align the second optical fiber with one of the m waveguide channels, the second splice means include fiber receiving slots formed in the first end of the substrate and m fiber alignment slots having first and second ends, the first ends thereof being in general aligned with the slots receiving the fiber respectively and the second ends of the fiber alignment slots are generally aligned with the m waveguide channels; and a housing surrounding the substrate, the waveguide element and the first and second splice means.
20. 20. The optical coupler according to claim 19, characterized in that: the first connecting means receive the first optical fiber in a reachable manner; and the second splice means receive the second optical fiber in a re-engageable manner.
21. 21. The optical coupler according to claim 19, characterized in that the channels of the waveguide are formed by microreplication of the waveguide element.
22. 22. The optical coupler according to claim 21, characterized in that the substrate comprises a first plate having first and followed ends and further comprising: a second plate; a third plate interposed between the first and second plates, the second plate has a recess to receive the third plate; and wedge means for driving the first and second splicing means, the wedge means causing the second plate to be driven forcefully against the first plate when the wedge means is in the actuated state.
23. 23. The optical coupler according to claim 22, characterized in that the first and third plates are adhered to each other by a polymerizable material which also forms a core of each of the channels of the waveguide.
24. 24. A microreplicated optical module for interconnecting optical fibers, characterized in that it comprises: a first plate having first and second ends and a central portion; an optical waveguide element formed integrally on the central portion of the first plate, the waveguide element includes n waveguide channels which divide or converge on m waveguide channels, all channels are filled With an optically transmitting material, where nm are independently integers from 1 to 1, 024 inclusive, each of the channels of the waveguide is formed by microreplication of the waveguide element, wherein the optically transmissive material is fills in the channels of the waveguide before the interconnection of the optical fibers by means of the module; a first splice element integrally formed on the first plate at the first end thereof, for receiving at least a first optical fiber in a re-engageable manner and aligning the first optical fiber with one of the n channels of the waveguide, the first splice element includes n grooves receiving the fiber, formed at the first end of the first plate and n fiber alignment slots having first and second ends, the first ends thereof being generally aligned with the n grooves receiving the fiber respectively and the second ends of the n fiber alignment slots are generally aligned with the n waveguide channels; a second splice element integrally formed on the first plate at the second end thereof, for receiving at least one second optical fiber in a re-engageable manner and aligning the second optical fiber with one of the m channels of the waveguide, the second splice element includes m receiving grooves formed in the first end of the first plate and m fiber alignment slots having first and second ends, the first ends thereof being in general aligned with the m slots which receive the fiber respectively and the second ends of the fiber alignment slots are generally aligned with the m waveguide channels; a second plate; a third plate interposed between the first and second plates, the second plate has a recess to receive the third plate and the first and third plates are adhered to each other by a polymerizable material which also forms a core of each of the channels of the waveguide; a housing that surrounds the first, second and third plates, the waveguide element and the first and second splice elements; and first and second means, attached to the housing, to independently actuate the first and second splice elements respectively, the actuation means cause the second plate to be driven in a forced manner against the first plate when the actuation means are in a state driven, to attach by this to any fiber positioned in the grooves that receive the fiber.