The present invention relates to a method for manufacturing an expanded beam connector for fiber arrays, including arbitrary ordering of the array (not necessarily linear array or square array). It consists in a lithography-based fabrication of a ferrules array and a wafer-level assembly.
Optical fiber connectivity requires high alignment precision. If the fibers are multimode, this precision can be obtained by so-called passive alignment, meaning that the alignment procedure does not require closed loop feed-back on the alignment quality measurement. The precision needed is in general in the several microns range and can be obtained by a pick-and-place procedure. However, when the connectivity of single-mode fibers is required, the situation is more complex. In the general case, active alignment is necessary (for example, alignment of a single-mode fiber to a free-space laser). However, in the case of single-mode connectors for single fibers, the technique employed is a combination of a sleeve and a ferrule. The ferrule and the sleeve are fabricated with a high precision (in the order of better than half a micron). The single-mode fiber is inserted within the ferrule, and two ferrules (corresponding to the two fibers that may be connected) are inserted within the same precisely machined sleeve. By providing long enough sleeves and ferrules, it is possible to precisely align the two fibers.
This method however is ill-suited for fiber connection in a dirty environment since a particle of a few microns can block the access to the fiber cores and generate large losses. It is obviously even more complex to align an array of such fibers. In order to deal with this problem, a common approach is to make use of microlenses whose focal points are at the fiber facets, leading to large beams that are much less sensitive to small dirt particles (so-called expanded beam connector). In addition, the alignment of two such expanded beam connectors is much less sensitive to small translational errors. However, this comes at the price of a very high sensitivity to angular alignment errors. This sensitivity can be reported to the connector itself, which is more complex to manufacture due to complex active alignment procedures that are both expensive and time consuming. Multiple single-mode fibers expanded connectors are considerably more complex to develop since in addition to the precise parallelism between the fiber facets, it is necessary to ensure parallelism between the fibers, compactness, multiple parallel connections and field operation. Assembly of commercial ferrules or sleeves leads to a large pitch array, which is not suitable in many situations. Other constraints include the possibility of replacing defective fiber, easy mounting of the fibers within the array and so on.
The present invention seeks to provide a method for manufacturing an expanded beam connector for fiber arrays, including arbitrary ordering of the array (not necessarily linear array or square array). It consists in a lithography-based fabrication of a ferrules array and a wafer-level assembly, as is described more in detail hereinbelow.
There is provided in accordance with a non-limiting embodiment of the invention a method for manufacturing an array of optical fiber ferrules including producing on a first side of a wafer a pattern of an array of disks or holes in a metallic coating, wherein a diameter of each of the disks or holes is equal to or greater than a diameter of an optical fiber, covering the metallic coating with a negative photoresist layer, illuminating a second side of the wafer opposite to the first side, the second side not being covered by the metallic coating, with light that propagates as a divergent or collimated beam through the photoresist layer, thereby creating a conical pattern within the photoresist layer, developing the photoresist layer to create conical apertures in the photoresist layer, and attaching a sheet with a conical openings pattern registered to the conical apertures in such a way that a small diameter of each conical opening of the sheet is smaller than, and in contact with, a large diameter of the conical aperture to which it is registered, thereby forming an array of optical fiber ferrules.
The angle of the divergent beam may be modified by controlling a numerical aperture of the illumination. Filling the voids may be done by immersing the wafer in an electroforming solution and the voids may be filled with metal that is electroformed.
The conical apertures may be conformally coated with a metallic coating. The metallic coating may be based on nickel. The conical apertures may be conformally coated with polytetrafluoroethylene.
The method may further include introducing an optical fiber in one of the optical fiber ferrules.
The method may further include stacking several the photoresist layers in order to obtain a cascade of conical apertures with decreasing apertures.
A method for manufacturing an optical fiber array includes producing an array of ferrules as described above and herein, coupling a space wafer to the array of ferrules (e.g., aligning and attaching a stop wafer to the array of ferrules, aligning and attaching a spacer wafer to the stop wafer), inserting a wedge in each of the openings of the spacer wafer, attaching a wafer of microlenses arrays to the spacer wafer, attaching an additional spacer wafer and a window to the spacer wafer to form a wafer assembly, and separating the wafer assembly into arrays.
The present invention will be understood and appreciated more fully from the following detailed description, taken in conjunction with the drawings in which:
The following is a non-limiting description of manufacturing the ferrules array.
First, the fabrication of the ferrules array wafer is described, and assumes that 200-300 nm resolution lithography is available. In the first stage (
The metallic coating is then covered with a negative photoresist such as SU8 photoresist. The thickness of the photoresist should be at least above 100 microns.
In the case of holed apertures (111) this can be obtained through spin-coating of liquid SU8 photoresist (201) (from Microchem Inc.), followed by lamination of SUEX thick sheets (202). In the case of transparent apertures in the glass substrate (112) this can be obtained directly through lamination of the SUEX sheets (203).
Then a uniform illumination (e.g., UV light 301) is provided on the back side of the wafer (the side that is not covered by the metallic coating) so that UV light is transmitted only through the holes (and is blocked by the metallic coating). Following the holes, light propagates according to divergent beams (one beam per hole), therefore creating a conical illumination pattern within the photoresist layer. The exact angle (302) of this conical pattern can be modified by controlling the numerical aperture of the UV illumination. The angle is chosen to be close enough to 90° so as to reduce friction as much as possible and ultimately ensure smooth gliding of the fiber inside the ferrule.
Following this illumination pattern, the photoresist is exposed, leaving inverted conical structures 401 in the photoresist layer. Between these structures the wafer is covered with the initial metallic thin coating 121/122. Then the wafer is immersed in an electroforming solution and the voids between the conical structures may be filled with metal that is electroformed (501). In order to improve the process, it is possible to first conformally coat the inverted SU8 conical structures with a metallic coating (for example using an atomic layer deposition technique) so that the inverted conical columns are entirely coated with metal.
Then the photoresist is removed, leaving conical apertures in a thick metallic layer 502. The small conical diameter 602 is d1=d_f+d_lith (the size of the holes opening), and the large conical diameter 603 is d2=d1+2T·tan(α), where T is the metallic layer thickness and a the angle of the walls with the normal to the wafer.
Then a metallic block of at least a few millimeters thick (601) is prepared with conical holes spatially arranged according to the pattern of holes described above, and whose small diameter 604 (including the manufacturing tolerance t_m and passive alignment tolerance t_a) lies between d1 and d2.
The large diameter is chosen so that an optical fiber can be easily introduced in the opening. This block is then passively aligned and attached to the wafer so that the axes of the conical apertures coincide (see
The divergence of the UV illumination may be chosen so that the aperture diameter at the outer metallic surface of the wafer 603 is a least a few microns larger than the aperture diameter at the wafer surface itself 602, and a, the angle between the walls and the normal to the wafer surface, is very small.
A slippery coating, such as polytetrafluoroethylene coating, can then be deposited conformally so that the walls of the conical apertures have a very low friction coefficient.
Accordingly, an optical fiber can be introduced in the outer opening of the metallic layer and is guided by the walls, first roughly (in the outer metallic layer) and then precisely (in the inner metallic layer). In the alternative where the holes in the substrate are through holes, the fibers that passed through both cones can be then cleaved and polished. The fibers are maintained in place either by using an adhesive layer between the fiber and the substrate, by filling the conical aperture with an adhesive material, by laser soldering the fiber and the substrate, by mechanically pressing the fiber against the wafer, or by mechanically gripping the fiber. A thin layer of index-matched oil can be introduced between the fiber and the wafer for better optical contact.
Having detailed the structure of the ferrules array wafer, an example for the whole connector structure is now presented. The connector may be manufactured using the so-called wafer-level assembly technology, where the whole structure is obtained by precisely aligning patterned wafers (of the same size), attaching them one to the other and then dicing them into individual devices. The advantage of this rapidly growing technology is that most active alignments procedures are performed at the wafer level, simultaneously for multiple devices, rather than for each device individually. Furthermore, this active alignment can be replaced by passive alignment of wafers with special 3D patterns that lock one into the other.
First, a patterned array geometry may be defined. The description follows for the non-limiting example of a five-by-five fibers array connector. The pitch of the array is 1 mm. The wafer is patterned with such arrays. For example, taking the preceding example, the ferrules arrays wafer is patterned with arrays of 5-by-5 disks with a pitch of 1 mm and a diameter of 126 microns. The pitch of the arrays (arrays center-to-center distance) is set to 8 mm in this example in both directions.
Following the procedure described above, a ferrules arrays wafer is prepared. Then a spacer wafer 701 is prepared. The spacer wafer is a wafer with holes in the exact position of the array. In our example, this wafer has square openings of 6 mm by 6 mm with a pitch identical to the pitch of the ferrules array wafer (8 mm). This wafer is then passively aligned and attached to the ferrules array wafer.
Next, a one-dimensional array of wedges 801 is inserted in the openings of the previous spacer wafer. The objective of this array is to emulate angle cleaved fibers. The procedure described above does not easily adapt to angle-cleaved fibers, so the fibers may be attached when their facet is parallel to the ferrules' arrays wafer. This causes a problem for back reflection. In order to remediate to this problem, an array of wedges may be added that disperses the light beams like angle-cleaved fibers. The wedge angle can be set to 8°, as the angle-cleaved fibers angle.
Each array of wedges can be individually placed in the openings (the positioning precision is around 100 microns, so pick-and-place techniques are sufficient) and attached to the ferrules arrays wafer. The spacer wafer may be chosen thick enough so that the top of the wedges is below the upper surface of the spacer wafer.
Next a wafer of microlenses arrays 802 is attached to the spacer wafer. The positioning of this wafer can be done actively using a small number of reference points. For example, three fibers can be attached at the ferrules array periphery, far one from the other, and light coupled in. At the output, a retroreflector is positioned and light that is reflected back is coupled back in the fiber if the microlenses arrays are aligned. By monitoring light that comes back from the fiber (using for example a circulator), it is possible to optimize the microlenses arrays alignment. The wafers are then attached one to the other.
An additional spacer wafer 803 is attached to the assembly and a window is attached to this spacer wafer. The wafer assembly is then tested in order to identify defective arrays.
The wafers assembly is then diced into 6 mm×6 mm arrays (inserts), and defective elements are discarded (
The last part of the assembly is the insertion of the previously described insert into a metallic enclosure. The beams that exit the insert have a large diameter. Therefore, their tolerance to translational assembly errors is large but they are very sensitive to angular assembly errors. The following describes how to take advantage of this for the final assembly.
The metallic enclosure 1001 (
An assembly jig (
Finally, a single wedge with the same angle as the wedges array described above, and with dimensions of 6 mm by 6 mm is attached to the window so that light exiting the connector is parallel to the connector axis (
In order to reduce back-reflections, free surfaces may be anti-reflection coated.
The metallic enclosure is then inserted into a spring loaded mount that allows physical contact of the two metallic enclosures.
In order to introduce the fibers, the following procedure can be used. A glass block of the same length and width as the insert is fabricated, with an array of holes corresponding to the array of microlenses. The hole diameter may be larger than the fiber diameter, but does not have to be precise. Then fibers are introduced in the holes and a thick layer of organic liquid material which can be polymerized is deposited on top of the glass block (between the fibers). After polymerization the block is polished and the fibers may be polished with exactly the right length. The glass block is then removed and the fibers introduced in the insert.
An alternative way to form the connector without the electroforming stage is now described.
Reference is now made to
On this wafer, a SUEX photoresist film (or equivalent) A203 is laminated or coated (
Uniform UV light A301 is then illuminated from the wafer's back side as shown in
In
Once the etching has been completed, the cross-linked SUEX layer is peeled off the substrate, resulting in a substrate free structure, as shown in
Once the different layers are prepared, they can be stacked one on top of the other, as shown on
In case of Angle Polished Fibers (APC fibers), the fibers can be inserted until a given depth using a stop layer as illustrated in
The angle compensation is provided by an additional prism A1001 (
The connector can be assembled at the chip level (single element) or at the wafer level. In such a case it is necessary to separate the different connectors after assembly (and gluing). This can be done using dicing, or alternatively, the wafers can be prepared in advance (at the lithographic stage) so that trenches A1201 are etched between the different connectors of the wafer assembly, and a weak mechanical link A1202 is left for mechanical support, as shown in
Filing Document | Filing Date | Country | Kind |
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PCT/IB2021/056901 | 7/29/2021 | WO |
Number | Date | Country | |
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63057898 | Jul 2020 | US |