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.

1 - 62 . (canceled) 
     
     
         63 . An optical coupling device for routing optical signals, comprising:
 a base;   at least a structured surface defined on the base, wherein the structured surface has a surface profile that reshapes and/or reflects an incident light; and   at least an alignment structure defined on the base, configured with a surface feature to facilitate positioning an optical component on the base in optical alignment with the structured surface to allow light to be transmitted along a defined path between the structured surface and the optical component,   wherein the structured surface and the alignment structure are integrally defined on the base by stamping a malleable material of the base,   wherein the alignment structure accurately aligns the optical fiber with respect to the structured reflective surface, so that output light from the optical fiber can be reflected by the structured reflective surface to outside the coupling device or input light from outside the coupling device incident at the structure reflective surface can be reflected towards the optical fiber.   
     
     
         64 . The optical coupling device as in  claim 63 , wherein the structured surface comprises a structured reflective surface having the surface profile, reflecting the incident light. 
     
     
         65 . The optical coupling device as in  claim 64 , wherein the surface profile comprises a curved surface profile, further reshaping the incident light. 
     
     
         66 . The optical coupling device as in  claim 65 , wherein the curved surface profile comprises a concave surface profile. 
     
     
         67 . The optical coupling device as in  claim 64 , wherein the surface profile comprises a flat reflective surface profile. 
     
     
         68 . The optical coupling device as in  claim 63 , wherein the surface feature comprises an optical fiber retention structure configured to secure an optical fiber in optical alignment with the structured surface. 
     
     
         69 . The optical coupling device as in  claim 68 , wherein the optical fiber retention structure comprises a groove defined on the base, wherein the groove is aligned with respect to the structured surface. 
     
     
         70 . The optical coupling device as in  claim 69 , 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. 
     
     
         71 . The optical coupling device as in  claim 69 , wherein the groove is an open groove. 
     
     
         72 . The optical coupling device as in  claim 71 , wherein the structured reflective surface and the open groove are formed by stamping the malleable material of the base. 
     
     
         73 . The optical coupling device as in  claim 63 , wherein the malleable material is metal. 
     
     
         74 . The optical coupling device as in  claim 63 , wherein the base comprises a monolithic body on which the structured surface and the alignment structure are defined by stamping. 
     
     
         75 . The optical coupling device as in  claim 64 , wherein the structured reflective surface is coated with a reflective material. 
     
     
         76 . The optical coupling device as in  claim 63 , wherein there are a plurality of structured surfaces and a plurality of alignment structures integrally defined on the base by stamping a malleable material of the base, wherein each alignment structure is configured with a surface feature to facilitate positioning an optical component on the base in optical alignment with the structured surface of a corresponding structure surface, to allow light to be transmitted along a defined path between the corresponding structured surface and optical component. 
     
     
         77 . The optical coupling device as in  claim 63 , wherein the surface feature facilitates passive alignment of the optical component on the base in optical alignment with the structured surface to allow light to be transmitted along a defined path between the structured surface and the optical component. 
     
     
         78 . A transmitter/receiver module, comprising:
 the optical coupling device as in  claim 63 ; and   at least one of a light source and a light detector supported with respect to the structured reflective surface, wherein the light source produces the input light to be reflected by the structured reflective surface and the light detector receives the output light reflected by the structured reflective surface.   
     
     
         79 . The module as in  claim 78 , wherein the light source is part of a transmitter, and the light detector is part of a receiver. 
     
     
         80 . An active optical cable, comprising:
 an optical fiber cable having at least one optical fiber;   a transmitter module as in  claim 78 , physical and optically coupled to a first end of the optical fiber; and   a receiver module as in  claim 78 , physically and optically coupled to a second end of the optical fiber.   
     
     
         81 . An optical coupling device for physically and optically coupling an optical fiber for routing optical signals, comprising:
 a base having a structured reflective surface and an optical fiber retention structure integrally defined thereon such that an end face of the optical fiber is located at a predetermined distance from the structured reflective surface along the axis of the optical fiber, wherein an end face of the optical fiber is located at a predetermined distance from the structured reflective surface along the axis of the optical fiber, wherein the structured reflective surface and the optical fiber retention structure are integrally defined by stamping a malleable material of the base, and wherein the optical fiber retention structure accurately aligns the optical fiber with respect to the structured reflective surface, so that output light from the optical fiber can be reflected by the structured reflective surface to outside the coupling device or input light from outside the coupling device incident at the structure reflective surface can be reflected towards the optical fiber.   
     
     
         82 . A method for forming an optical coupling device for routing optical signals, comprising:
 stamping a blank of a malleable material, to form at least a base, and integrally define on the base structures that comprises:   a structured surface defined on the base, wherein the structured surface has a surface profile that reshapes and/or reflect an incident light; and   an alignment structure defined on the base, configured with a surface feature to facilitate positioning an optical component on the base in optical alignment with the structured surface to allow light to be transmitted along a defined path between the structured surface and the optical component.