Hermetic optical fiber alignment assembly having integrated optical element

Abstract

A hermetic optical fiber alignment assembly includes a ferrule portion having a plurality of grooves receiving the end sections of optical fibers, wherein the grooves define the location and orientation of the end sections with respect to the ferrule portion. The assembly includes an integrated optical element for coupling the input/output of an optical fiber to the opto-electronic devices in the opto-electronic module. The optical element can be in the form of a structured reflective surface. The end of the optical fiber is at a defined distance to and aligned with the structured reflective surface. The structured reflective surfaces and the fiber alignment grooves can be formed by stamping.

We claim: 
     
         1 . A hermetic optical fiber alignment assembly, comprising:
 a first ferrule portion having a first surface defining at least a groove receiving at least an end section of an optical fiber, wherein groove defines the location and orientation of the end section with respect to the first ferrule portion;   a second ferrule portion having a second surface facing the first surface of the first ferrule, wherein the first ferrule portion is hermetically attached to the second ferrule portion with the first surface against the second surface,   wherein the first ferrule includes an extended portion beyond an edge of the second ferrule portion, on which the groove extends and terminates at an optical element located beyond the edge of the second ferrule portion, wherein an end face of the optical fiber is located at a predetermined distance from the optical element along the axis of the optical fiber, and wherein the groove accurately aligns the optical fiber with respect to the optical element, so that output light from the optical fiber can be directed by the optical element to outside the ferrule or input light from outside the ferrule incident at the optical element can be directed towards the optical fiber.   
     
     
         2 . The hermetic optical fiber alignment assembly as in  claim 1 , wherein the optical element is integral to the ferrule. 
     
     
         3 . The hermetic optical fiber alignment assembly as in  claim 2 , wherein the optical element and the ferrule are part of a same monolithic structure. 
     
     
         4 . The hermetic optical fiber alignment assembly as in  claim 2 , wherein the optical element comprises a structured reflective surface, where the groove extends and terminates at the structured reflective surface, wherein output light from the optical fiber can be reflected by the structured reflective surface to outside the ferrule or input light from outside the ferrule incident at the structured reflective surface can be reflected towards the optical fiber. 
     
     
         5 . The coupling device as in  claim 4 , wherein the groove is aligned with respect to the structured reflective surface. 
     
     
         6 . The coupling device as in  claim 5 , wherein the groove includes a shoulder that defines a stop to which a portion of the end face of the optical fiber can butt against to define the predetermined distance between the end face of the optical fiber and the structured reflective surface. 
     
     
         7 . The coupling device as in  claim 6 , wherein the groove is precision formed to align the optical fiber with respect to the structured reflective surface. 
     
     
         8 . The coupling device as in  claim 7 , wherein the groove is an open groove on the first ferrule portion. 
     
     
         9 . The coupling device as in  claim 8 , wherein the structured reflective surface and the open groove are formed by stamping a malleable material. 
     
     
         10 . The coupling device as in  claim 9 , wherein the malleable material is metal. 
     
     
         11 . The coupling device as in  claim 1 , wherein the structured reflective surface is concave. 
     
     
         12 . An opto-electronic module, comprising:
 a housing; and   a hermetic optical fiber alignment assembly as in  claim 1 , hermetically sealed to the housing.   
     
     
         13 . An opto-electronic module, comprising:
 a housing; and   a hermetic optical fiber alignment assembly as in  claim 1 , hermetically sealed to the house, forming a terminal for external connection by an alignment sleeve.   
     
     
         14 . The hermetic optical fiber alignment assembly as in  claim 1 , wherein there are a plurality of optical fibers and a plurality of grooves each receiving at least the end section of one of the optical fibers, and each groove terminates at a structured reflective surface. 
     
     
         15 . A process of making the hermetic optical fiber alignment assembly of  claim 1 , comprising:
 stamping a ferrule to form a structured reflective surface and at least an optical fiber alignment groove, wherein the groove is aligned with respect to the structured reflective surface.   
     
     
         16 . A hermetic optical fiber alignment assembly, comprising:
 a first ferrule portion defining an optical element and an optical fiber retention structure such that an end face of the optical fiber is located at a predetermined distance from the optical element along the axis of the optical fiber, wherein an end face of the optical fiber is located at a predetermined distance from the optical element along the axis of the optical fiber, and wherein the optical fiber retention structure accurately aligns the optical fiber with respect to the optical element, so that output light from the optical fiber can be directed by the optical element to outside the first ferrule portion or input light from outside the first ferrule portion incident at the optical element can be reflected towards the optical fiber; and   a second ferrule portion hermetically attached to the second ferrule portion,   wherein the first ferrule includes an extended portion beyond an edge of the second ferrule portion, on which the optical element is located beyond the edge of the second ferrule portion.   
     
     
         17 . A hermetic optical fiber alignment assembly as in  claim 16 , wherein the optical fiber retention structure comprises an alignment groove sized to receive at least an end section of the optical fiber.