Coupling device having a structured reflective surface for coupling input/output of an optical fiber

Abstract

A coupling device for physically and optically coupling an input/output end of an optical fiber for routing optical signals, to and from optical receiver and/or transmitter. The coupling device includes a structured reflective surface that functions as an optical element that directs light to/from the input/output ends of the optical fiber by reflection, and an optical fiber retention groove structure that positively receives the optical fiber in a manner with the end of the optical fiber at a defined distance to and aligned with the structured reflective surface. The open structure of the structured reflective surface and fiber retention structure lends itself to mass production processes such as precision stamping. The coupling device can be attached to an optical transmitter and/or receiver, with the structured reflective surface aligned to the light source in the transmitter or to the detector in the receiver, and adapted in an active optical cable.

We claim: 
     
         1 . A modified transistor-outline (TO)-can assembly comprising:
 a header having at least an upper surface and a lower surface, the lower surface of the header corresponding to the lower surface of the modified TO-can assembly;   an optical subassembly (OSA) disposed on the upper surface of the header, the OSA including at least an optoelectronic device;   a collar having at least an upper surface, a lower surface, an inner surface, and an outer surface, the inner and outer surfaces of the collar defining a side wall of the collar;   a receptacle having at least a top surface, a bottom surface, and an outer wall, wherein the outer wall defines a side wall of the receptacle, wherein a portion of the outer wall of the receptacle is mechanically coupled to a portion of the inner surface of the collar, and wherein an opening is formed in the side wall of the collar and an opening is formed in the side wall of the receptacle for receiving a portion of an optical fiber in the modified TO-can assembly at a non-zero degree angle, α, relative to an axis of the modified TO-can assembly that is generally normal to the upper surface and lower surface of the collar and the top surface and bottom surface of the receptacle;   a cap having at least an upper surface, a lower surface, an inner surface, and an outer surface, the inner and outer surfaces of the cap defining a side wall of the cap, a portion of the lower surface of the cap being mechanically coupled to a portion of the upper surface of the header, wherein a portion of the lower surface of the collar is mechanically coupled to a portion of the upper surface of the cap; and   a window having at least an upper surface and a lower surface, the upper surface of the window being mechanically coupled to the inner surface of the cap about a peripheral portion of the window, the window being transparent to an operational wavelength of the optoelectronic device is affixed to the bottom surface of the receptacle.   
     
     
         2 . The modified TO-can assembly of  claim 1 , wherein α ranges from approximately 70° to approximately 110° relative to the axis of the modified TO-can assembly that is generally normal to the upper surface and lower surface of the collar and the top surface and bottom surface of the receptacle. 
     
     
         3 . The modified TO-can assembly of  claim 2 , wherein α is approximately 90°. 
     
     
         4 . The modified TO-can assembly of  claim 3 , further comprising:
 at least one reflector that folds an optical pathway within the modified TO-can assembly by the angle α.   
     
     
         5 . The modified TO-can assembly of  claim 1 , wherein the bottom surface of the receptacle has a groove formed in it having a length-wise axis, the groove being adapted to accept the portion of the optical fiber that is received by the opening formed in the outer wall of the receptacle. 
     
     
         6 . The modified TO-can assembly of  claim 5 , further comprising:
 a first reflector that folds an optical pathway within the modified TO-can assembly by the angle α.   
     
     
         7 . The modified TO-can assembly of  claim 6 , wherein the bottom surface of the receptacle has a recess formed therein adjacent an end of the groove, and wherein the first reflector is disposed in the receptacle opposite the end of the groove. 
     
     
         8 . The modified TO-can assembly of  claim 1 , wherein a combination of the opening formed in the side wall of the receptacle and the opening formed in the side wall of the collar comprises an opening formed in a side wall of the modified TO-can assembly. 
     
     
         9 . The modified TO-can assembly of  claim 1 , wherein the bottom surface of the receptacle has a groove formed in it having a length-wise axis, and wherein the portion of the optical fiber that is affixed to the bottom surface of the receptacle is disposed within the groove such that the optical axis of the portion of the optical fiber is parallel to the length-wise axis of the groove. 
     
     
         10 . The modified TO-can assembly of  claim 9 , wherein α ranges from approximately 70° to approximately 110° relative to the axis of the modified TO-can assembly that is generally normal to the upper surface and lower surface of the collar and the top surface and bottom surface of the receptacle. 
     
     
         11 . The modified TO-can assembly of  claim 10 , wherein α is approximately 90°. 
     
     
         12 . The modified TO-can assembly of  claim 1 , wherein the optoelectronic device is a laser diode. 
     
     
         13 . The modified TO-can assembly of  claim 1 , wherein the optoelectronic device is a photodiode. 
     
     
         14 . A modified transistor outline (TO)-can assembly comprising:
 a header having at least an upper surface and a lower surface;   an optical subassembly (OSA) disposed on the upper surface of the header, the OSA including at least an optoelectronic device;   a cap having at least an upper surface, a lower surface, an inner surface, and an outer surface, the inner and outer surfaces of the cap defining a side wall of the cap, a portion of the lower surface of the cap being mechanically coupled to a portion of the upper surface of the header;   a window having at least an upper surface and a lower surface, the upper surface of the window being mechanically coupled to the inner surface of the cap about a peripheral portion of the window, the window being transparent to an operational wavelength of the optoelectronic device;   a collar having at least an upper surface, a lower surface, an inner surface, and an outer surface, the inner and outer surfaces of the collar defining a side wall of the collar, wherein a portion of the lower surface of the collar is mechanically coupled to a portion of the upper surface of the cap; and   a receptacle having at least a top surface, a bottom surface and an outer wall, a portion of the outer wall of the receptacle being mechanically coupled to a portion of the inner surface of the collar, wherein the bottom surface of the receptacle has a groove formed in it having a length-wise axis, the groove being adapted to receive a portion of an optical fiber that is passed through an opening formed in the outer wall of the receptacle and an opening formed in the side wall of the collar and wherein the portion of the optical fiber has an optical axis that is parallel to the length-wise axis of the groove, the length-wise axis of the groove being at a non-zero degree angle, α, to an axis of the modified TO-can assembly that is generally normal to the upper surface and lower surface of the collar and the top surface and bottom surface of the receptacle.   
     
     
         15 . The modified TO-can assembly of  claim 14 , wherein α ranges from approximately 70° to approximately 110° relative to the axis of the modified TO-can assembly that is generally normal to the upper surface and lower surface of the collar and the top surface and bottom surface of the receptacle. 
     
     
         16 . The modified TO-can assembly of  claim 15 , wherein α is approximately 90°. 
     
     
         17 . The modified TO-can assembly of  claim 14 , further comprising:
 a first reflector that folds an optical pathway within the modified TO-can assembly by the angle α.   
     
     
         18 . The modified TO-can assembly of  claim 17 , wherein the bottom surface of the receptacle has a recess formed therein adjacent an end of the groove, and wherein the first reflector is disposed in the receptacle opposite the end of the groove. 
     
     
         19 . The modified TO-can assembly of  claim 14 , wherein the optoelectronic device is a laser diode. 
     
     
         20 . The modified TO-can assembly of  claim 14 , wherein the optoelectronic device is a photodiode. 
     
     
         21 . A modified transistor-outline (TO)-can assembly comprising:
 a header having at least an upper surface and a lower surface, the lower surface of the header corresponding to the lower surface of the modified TO-can assembly;   an optical subassembly (OSA) disposed on the upper surface of the header, the OSA including at least an optoelectronic device;   a collar having at least an upper surface, a lower surface, an inner surface, and an outer surface, the inner and outer surfaces of the collar defining a side wall of the collar;   a receptacle having at least a top surface, a bottom surface, and an outer wall, wherein the outer wall defines a side wall of the receptacle, wherein a portion of the outer wall of the receptacle is mechanically coupled to a portion of the inner surface of the collar, wherein an opening is formed in the side wall of the collar and an opening is formed in the side wall of the receptacle for receiving a portion of an optical fiber in the modified TO-can assembly at a non-zero degree angle, α, relative to an axis of the modified TO-can assembly that is generally normal to the upper surface and lower surface of the collar and the top surface and bottom surface of the receptacle, and wherein the portion of the optical fiber that is received by the opening in the side wall of the receptacle is affixed to the bottom surface of the receptacle;   a cap having at least an upper surface, a lower surface, an inner surface, and an outer surface, the inner and outer surfaces of the cap defining a side wall of the cap, a portion of the lower surface of the cap being mechanically coupled to a portion of the upper surface of the header, wherein a portion of the lower surface of the collar is mechanically coupled to a portion of the upper surface of the cap; and   a window having at least an upper surface and a lower surface, the upper surface of the window being mechanically coupled to the inner surface of the cap about a peripheral portion of the window, the window being transparent to an operational wavelength of the optoelectronic device.   
     
     
         22 . The modified TO-can assembly of  claim 21 , wherein α ranges from approximately 70° to approximately 110° relative to the axis of the modified TO-can assembly that is generally normal to the upper surface and lower surface of the collar and the top surface and bottom surface of the receptacle. 
     
     
         23 . The modified TO-can assembly of  claim 22 , wherein α is approximately 90°. 
     
     
         24 . The modified TO-can assembly of  claim 23 , further comprising:
 at least one reflector that folds an optical pathway within the modified TO-can assembly by the angle α.   
     
     
         25 . The modified TO-can assembly of  claim 21 , wherein the bottom surface of the receptacle has a groove formed in it having a length-wise axis, the groove being adapted to accept the portion of the optical fiber that is received by the opening formed in the outer wall of the receptacle. 
     
     
         26 . The modified TO-can assembly of  claim 25 , further comprising:
 a first reflector that folds an optical pathway within the modified TO-can assembly by the angle α.   
     
     
         27 . The modified TO-can assembly of  claim 26 , wherein the bottom surface of the receptacle has a recess formed therein adjacent an end of the groove, and wherein the first reflector is disposed in the receptacle opposite the end of the groove. 
     
     
         28 . The modified TO-can assembly of  claim 21 , wherein a combination of the opening formed in the side wall of the receptacle and the opening formed in the side wall of the collar comprises an opening formed in a side wall of the modified TO-can assembly. 
     
     
         29 . The modified TO-can assembly of  claim 21 , wherein the bottom surface of the receptacle has a groove formed in it having a length-wise axis, and wherein the portion of the optical fiber that is affixed to the bottom surface of the receptacle is disposed within the groove such that the optical axis of the portion of the optical fiber is parallel to the length-wise axis of the groove. 
     
     
         30 . The modified TO-can assembly of  claim 29 , wherein α ranges from approximately 70° to approximately 110° relative to the axis of the modified TO-can assembly that is generally normal to the upper surface and lower surface of the collar and the top surface and bottom surface of the receptacle. 
     
     
         31 . The modified TO-can assembly of  claim 30 , wherein α is approximately 90°. 
     
     
         32 . The modified TO-can assembly of  claim 21 , wherein the optoelectronic device is a laser diode. 
     
     
         33 . The modified TO-can assembly of  claim 21 , wherein the optoelectronic device is a photodiode. 
     
     
         34 . An integrated transmitter/receiver module comprising:
 a transmitter/receiver portion having at least an upper surface and a lower surface, the lower surface of the header corresponding to the lower surface of the integrated transmitter/receiver module;   an optoelectronic device assembly disposed on the upper surface of the header, the optoelectronic device assembly including at least an optoelectronic device; and   a coupling device portion having at least a top surface, a bottom surface, and an outer wall, wherein the outer wall defines a side wall of the coupling device portion, wherein an opening is formed in the side wall of the coupling device portion for receiving a portion of an optical fiber in the integrated transmitter/receiver module at a non-zero degree angle, α, relative to an axis of the integrated transmitter/receiver module that is generally normal to the top surface and bottom surface of the coupling device portion, wherein a portion of the optical fiber is affixed to the bottom surface of the coupling device portion, and wherein the optoelectronic device assembly is sealed against the coupling device portion.   
     
     
         35 . The integrated transmitter/receiver module of  claim 34 , wherein α ranges from approximately 70° to approximately 110° relative to the axis of the integrated transmitter/receiver module that is generally normal to the top surface and bottom surface of the coupling device portion. 
     
     
         36 . The integrated transmitter/receiver module of  claim 35 , wherein α is approximately 90°. 
     
     
         37 . The integrated transmitter/receiver module of  claim 36 , further comprising:
 at least one reflector that folds an optical pathway within the integrated transmitter/receiver module by the angle α.   
     
     
         38 . The integrated transmitter/receiver module of  claim 34 , wherein the bottom surface of the coupling device portion has a groove formed in it having a length-wise axis, the groove being adapted to accept the portion of the optical fiber that is received by the opening formed in the outer wall of the coupling device portion. 
     
     
         39 . The integrated transmitter/receiver module of  claim 38 , further comprising:
 a first reflector that folds an optical pathway within the integrated transmitter/receiver module by the angle α.   
     
     
         40 . The integrated transmitter/receiver module of  claim 39 , wherein the bottom surface of the coupling device portion has a recess formed therein adjacent an end of the groove, and wherein the first reflector is disposed in the coupling device portion opposite the end of the groove. 
     
     
         41 . The integrated transmitter/receiver module of  claim 34 , wherein the opening formed in the side wall of the coupling device portion comprises an opening formed in a side wall of the integrated transmitter/receiver module. 
     
     
         42 . The integrated transmitter/receiver module of  claim 34 , wherein the bottom surface of the coupling device portion has a groove formed in it having a length-wise axis, and wherein the portion of the optical fiber that is affixed to the bottom surface of the coupling device portion is disposed within the groove such that the optical axis of the portion of the optical fiber is parallel to the length-wise axis of the groove. 
     
     
         43 . The integrated transmitter/receiver module of  claim 42 , wherein α ranges from approximately 70° to approximately 110° relative to the axis of the integrated transmitter/receiver module that is generally normal to the top surface and bottom surface of the coupling device portion. 
     
     
         44 . The integrated transmitter/receiver module of  claim 43 , wherein α is approximately 90°. 
     
     
         45 . The integrated transmitter/receiver module of  claim 34 , wherein the optoelectronic device is a laser diode. 
     
     
         46 . The integrated transmitter/receiver module of  claim 34 , wherein the optoelectronic device is a photodiode. 
     
     
         47 . An integrated transmitter/receiver module comprising:
 a transmitter/receiver portion having at least an upper surface and a lower surface;   an optoelectronic device assembly disposed on the upper surface of the transmitter/receiver portion, the optoelectronic device assembly including at least an optoelectronic device; and   a coupling device portion having at least a top surface, a bottom surface and an outer wall wherein the bottom surface of the coupling device portion has a groove formed in it having a length-wise axis, the groove being adapted to receive a portion of an optical fiber that is passed through an opening formed in the outer wall of the coupling device portion, wherein the portion of the optical fiber has an optical axis that is parallel to the length-wise axis of the groove, the length-wise axis of the groove being at a non-zero degree angle, α, to an axis of the integrated transmitter/receiver module that is generally normal to the top surface and bottom surface of the coupling device portion, and wherein the optoelectronic device assembly is sealed against the coupling device portion.   
     
     
         48 . The integrated transmitter/receiver module of  claim 47 , wherein α ranges from approximately 70° to approximately 110° relative to the axis of the integrated transmitter/receiver module that is generally normal to the top surface and bottom surface of the coupling device portion. 
     
     
         49 . The integrated transmitter/receiver module of  claim 48 , wherein α is approximately 90°. 
     
     
         50 . The integrated transmitter/receiver module of  claim 47 , further comprising:
 a first reflector that folds an optical pathway within the integrated transmitter/receiver module by the angle α.   
     
     
         51 . The integrated transmitter/receiver module of  claim 50 , wherein the bottom surface of the coupling device portion has a recess formed therein adjacent an end of the groove, and wherein the first reflector is disposed in the coupling device portion opposite the end of the groove. 
     
     
         52 . The integrated transmitter/receiver module of  claim 47 , wherein the optoelectronic device is a laser diode. 
     
     
         53 . The integrated transmitter/receiver module of  claim 47 , wherein the optoelectronic device is a photodiode. 
     
     
         54 . The integrated transmitter/receiver module of  claim 36 , further comprising:
 at least one structured reflective surface that folds an optical pathway within the integrated transmitter/receiver module by the angle α.   
     
     
         55 . The integrated transmitter/receiver module of  claim 38 , further comprising:
 a first structured reflective surface that folds an optical pathway within the integrated transmitter/receiver module by the angle α.   
     
     
         56 . The integrated transmitter/receiver module of  claim 55 , wherein the bottom surface of the coupling device portion has a recess formed therein adjacent an end of the groove, and wherein the first structured reflective surface is disposed in the coupling device portion opposite the end of the groove. 
     
     
         57 . The integrated transmitter/receiver module of  claim 47 , further comprising:
 a first structured reflective surface that folds an optical pathway within the integrated transmitter/receiver module by the angle α.   
     
     
         58 . The integrated transmitter/receiver module of  claim 57 , wherein the bottom surface of the coupling device portion has a recess formed therein adjacent an end of the groove, and wherein the first structured reflective surface is disposed in the coupling device portion opposite the end of the groove. 
     
     
         59 . The integrated transmitter/receiver module of  claim 34 , wherein the optoelectronic device is a light source. 
     
     
         60 . The integrated transmitter/receiver module of  claim 34 , wherein the optoelectronic device is a laser. 
     
     
         61 . The integrated transmitter/receiver module of  claim 47 , wherein the optoelectronic device is a light source. 
     
     
         62 . The integrated transmitter/receiver module of  claim 47 , wherein the optoelectronic device is a laser.