What is Claimed is:
1. Optical fiber array apparatus (10) comprising: a relatively thick primary substrate (12) having sufficient structure to support an array of N spaced-apart optical fibers and having first and second opposing surfaces (15, 19) and defining a plurality of N primary substrate apertures (14) which each extend therethrough from the first surface to the second surface with a cross-section of each of the N substrate apertures being greater than a cross-section of an optical fiber such that one optical fiber can be passed through in each of the N primary substrate apertures, each optical fiber comprising a cladding layer (32) surrounding an optical core (34) ; and a relatively thin first layer (20) , which has insufficient structure by itself to support an array of N spaced-apart optical fibers, engaging the second surface (19) of the primary substrate and defining N apertures (24) therethrough with centers of the first layer apertures being aligned to a preselected tolerance value which is that required for the array of optical fibers, the smallest cross-section of each of the first layer apertures being less than the smallest cross-section of each primary substrate apertures, each first layer aperture being within a footprint of one of the primary substrate apertures such that optical fibers inserted through the primary substrate apertures enter the first layer apertures, and the cross-sections of the first layer apertures having limited variations that result in spacings between adjacent optical fibers placed in the primary substrate apertures and entering the first layer apertures being within the preselected tolerance value such that optical fibers are aligned within the preselected tolerance value. 2. The optical fiber array apparatus of claim l wherein the first layer apertures have a cross-section which is greater than the cross-section of the cladding layer and optical core of each of the optical fibers and
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primary substrate apertures and the first layer apertures by the vacuum applied to the vacuum substrate once the N optical fibers are positioned and aligned in the primary substrate to the preselected tolerance value required for the array.
14. The optical fiber array apparatus of claim 13 wherein the vacuum substrate is displaceable in a direction orthogonal to the major surface of the first layer while applying a tension on each of the N optical fibers, and the vacuum substrate is also selectively displaceable in a direction parallel to the major surface of the layer for concurrently aligning and holding each of the N optical fibers in the associated first layer aperture while the bonding material cures . 15. The optical fiber array apparatus of claim 1 wherein once the N optical fibers are positioned through the primary substrate apertures and aligned in the first layer apertures within the preselected tolerance value required for the array and bonded in place, the N optical fibers are cleaved and exposed ends (30a) of the N optical fibers are ground and polished (a) to the second surface (19) of the primary substrate when the layer is removed, and (b) to the exposed surface (25) of the first layer when the first layer remains in engagement with the second surface of the primary substrate.
16. The optical fiber array apparatus of claim 15 wherein the relatively thin first layer of metal is one of a group consisting of stainless steel, nickel cobalt, carbon steel, aluminum, copper, and nickel. 17. The optical fiber array apparatus of claim 15 wherein the relatively thin first layer is an electroformed metal.
18. The optical fiber array apparatus of claim 1 wherein the primary substrate is one of the group consisting of Macor™, ceramic, plastic, and silicon.
19. The apparatus of claim 1 further comprising: a relatively thin second layer (60) engaging the first surface (15) of the primary substrate and defining N apertures (64) therethrough; the second layer apertures each having an edge thereof which is within the footprint of a primary substrate aperture such that optical fibers inserted through the second layer apertures, the primary substrate apertures, and the first layer apertures are positioned at a preselected angle (φ) relative to a primary axis (39) thereof.
20. The optical fiber array apparatus of claim 19 wherein the relatively thin second layer is a metal .
21. The apparatus of claim 19 wherein the preselected angle is essentially 0 degrees.
22. The apparatus of claim 19 wherein the preselected angle is an acute angle.
23. The apparatus of claim 1 further comprising: a relatively thin second layer (60) engaging the first surface (15) of the primary substrate and defining N apertures (64) therethrough; the second layer apertures being essentially the same size as the first layer apertures and being separated from the first layer apertures by the primary substrate and with the centers thereof being aligned with the centers of the first layer apertures such that optical fibers inserted through the second layer apertures, the primary substrate apertures, and the first layer apertures are positioned essentially perpendicular to a primary axis of the primary substrate.
24. The optical fiber array apparatus of claim 23 wherein the relatively thin second layer is a metal.
25. The apparatus of claim 1 further comprising: a relatively thin second layer (60) engaging the first surface (15) of the primary substrate and defining N apertures (64) therethrough; the second layer apertures being essentially the same size as the first layer apertures, being
separated from the first layer apertures by the primary substrate, and having the centers thereof spaced from the centers of the first layer apertures such that optical fibers inserted through the second layer apertures, the primary substrate apertures, and the first layer apertures are positioned at a preselected acute angle (φ) relative to a primary axis (39) thereof.
26. The optical fiber array apparatus of claim 25 wherein the relatively thin second layer is a metal. 27. The apparatus of claim 1 further comprising: a relatively thin second layer (60) engaging the first surface (15) of the primary substrate and defining N apertures (64) therethrough; the second layer apertures being larger than the first layer apertures, being separated from the first layer apertures by the primary substrate, and each having an edge which is within a footprint of one of the primary substrate apertures and is spaced apart from one edge of one of the first layer apertures such that optical fibers inserted through the second layer apertures, the primary substrate apertures, and the first layer apertures are positioned at a preselected acute angle (φ) relative to a primary axis (39) thereof.
28. The optical fiber array apparatus of claim 27 wherein the relatively thin second layer is a metal.
29. The apparatus of claim 1 further comprising: a relatively thin second layer (60) engaging the first surface of the primary substrate and defining N apertures (64) therethrough; the second layer apertures being larger than the first layer apertures, being separated from the first layer apertures by the primary substrate, and each having an edge which is within a footprint of one of the primary substrate apertures and is spaced apart from one edge of one of the first layer apertures such that optical fibers inserted through the second layer apertures, the primary substrate apertures, and the first layer apertures are
positioned essentially perpendicular to a major axis of the primary substrate.
30. The optical fiber array apparatus of claim 29 wherein the relatively thin second layer is a metal. 31. Optical fiber array apparatus (10) comprising: a relatively thick primary substrate (12) having sufficient structure to support an array of N spaced-apart optical fibers (30) and having first and second opposing surfaces (15, 19) and defining a plurality of N primary substrate apertures (14) which each extend therethrough from the first surface to the second surface with a cross-section of each of the N substrate apertures being greater than a cross-section of an optical fiber such that one optical fiber can be passed through in each of the N primary substrate apertures, each optical fiber comprising a cladding layer (32) surrounding an optical core (34) ; and a relatively thin first layer (20) , which has insufficient structure by itself to support an array of N spaced-apart optical fibers, engaging the second surface (19) of the primary substrate and defining N apertures (14) therethrough with centers of the first layer apertures being aligned to a preselected tolerance value which is that required for the array of optical fibers, the smallest cross-section of each of the first layer apertures being less than the smallest cross-section of each primary substrate apertures and being greater than the cross-section of a cladding layer and an optical core, each first layer aperture being within a footprint of one of the primary substrate apertures such that the cladding layers and the surrounded optical cores inserted through the primary substrate apertures pass can pass through the first layer apertures, and the cross-sections of the first layer apertures having limited variations that result in spacings between the cladding layers of adjacent optical fibers passing through the primary substrate apertures and the first layer apertures being within the preselected tolerance value such that the
optical fibers are aligned within the preselected tolerance value.
32. The optical fiber array apparatus of claim 31 wherein the relatively thin first layer is an electroformed metal.
33. The optical fiber array apparatus of claim 31 wherein the relatively thin first layer is a metal of a group consisting of stainless steel, nickel cobalt, carbon steel, aluminum, copper, and nickel. 34. The apparatus of claim 31 wherein the primary substrate is one of the group consisting of Macor , ceramic, plastic, and silicon.
35. The apparatus of claim 31 further comprising: a relatively thin second layer (60) engaging the first surface (15) of the primary substrate and defining N apertures (64) therethrough; the second layer apertures each having an edge thereof which is within the footprint of a primary substrate aperture such that optical fibers inserted through the second layer apertures, the primary substrate apertures, and the first layer apertures are positioned at a preselected angle (φ) relative to a primary axis (39) thereof.
36. The apparatus of claim 35 wherein the preselected angle is essentially 0 degrees.
37. The apparatus of claim 35 wherein the preselected angle is an acute angle.
38. The optical fiber array apparatus of claim 35 wherein the relatively thin second layer is a metal . 39. The apparatus of claim 31 further comprising: a relatively thin second layer (60) engaging the first surface (15) of the primary substrate and defining N apertures (64) therethrough; the second layer apertures being essentially the same size as the first layer apertures and being separated from the first layer apertures by the primary substrate and with the centers thereof being aligned with the centers of the first layer apertures such that
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a relatively thin second layer (60) engaging the first surface (15) of the primary substrate and defining N apertures (64) therethrough; the second layer apertures being larger than the first layer apertures, being separated from the first layer apertures by the primary substrate, and each having an edge which is within a footprint of one of the primary substrate apertures and is spaced apart from one edge of one of the first layer apertures such that optical fibers inserted through the second layer apertures, the primary substrate apertures, and the first layer apertures are positioned at a preselected acute angle (φ) relative to a primary axis (39) thereof.
46. The optical fiber array apparatus of claim 45 wherein the relatively thin second layer is a metal.
47. A method of forming an array apparatus (10), which supports N spaced-apart optical fibers (30) to a preselected tolerance value, the method comprising the steps of: (a) forming, in a relatively thick primary substrate (12) having sufficient structure to support an array of N spaced-apart optical fibers, N substrate apertures (14) which each extend therethrough from a first surface (15) of the primary substrate to a second surface (19) of the primary substrate with a cross- section of each of the N primary substrate apertures being greater than a cross-section of an optical fiber such that one optical fiber can be passed through each of the N primary substrate apertures; (b) forming a relatively thin first layer (20) defining N apertures (24) therethrough with centers of the first layer apertures being aligned to the preselected tolerance value which is that required for the array of optical fibers, the size of the cross- section of each of the layer apertures being less than the size of the cross-section of each primary substrate aperture;
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H > μ- CO Φ 3 fl Ω Ω Ω fD Φ Ω ti O Φ rr Hi TJ μ- μ- tr TJ TJ TJ CO tr f H
3 rr fu Φ 3" ti O ^-. CQ ri ri rr fu O μ- Φ CO μ- ri ≥! LQ li φ fD Φ Φ CQ d μ- ti ^ fD μ- TJ 3 rr O ii *» Φ d Φ Φ rr fl ti d ii μ- 3 CQ Ω ti ri d Ω 3 ^ ti 3 H" fu 3" O CO ϋ *» 3 ri fu μ- P. Φ fD μ- cr CQ 3 o φ rr TJ μ- rr rr cr 3' rr
^ d 3 Φ ri r-h CO Φ • — • rr Hi 3 O SD fD CQ rr fD TJ Pi fl 3 d d CQ fu CQ 3*
Φ fl 3 O CO fD μ- rr CQ H rr ri rr μ- LQ ti ii rr rr d μ-
CQ fu fu Φ Pi d rr CQ TJ « CO Ω LQ μ- 0 μ- rr CO fl ^ μ- a. fD 3 CQ Φ Φ ri tr Hi cr 3 d Ω X LQ 3" Φ O tr d Φ 3 rr O o ^-, $D fD Ω μ- ^ D Q Q fu SD o CQ cr 3" μ- TJ O tr Φ Ω a Φ cr 3 Φ 3" Ω cn rr "< CQ fD rr φ n cr rr rr o rr Hi
CO rr O Hi »• rr P. π CO ^-. φ CQ ri fD μ- o Φ Φ d H tr n *• Φ r Φ rr μ- rr O ^ O TJ μ- μ- Φ rr H 3 rr fD rr rr $D «— * ri cr μ- rr fD fD 0 TJ $D fl ti Hi φ rr l-1 o 3 ϋ LΠ rr Φ 3 3" rr rr $D CO Hi 3 fD CQ * < 3 fD TJ fl rr CQ fu O Pi tr d 3 LQ rr fD — - TJ Ω φ fu Φ rr TJ * rr μ- TJ d Φ μ- Pi TJ rr μ- Φ rr rr rr Hi φ fl 3* rr CQ φ Ω Pi 0 Φ tr fl cr rr Φ cr Φ
^-, 3 Φ μ- 3
Φ 3" CQ fu * fu φ Φ o d O tr ri μ- $D Φ 3* π CQ 3 LQ rr ri Ω rr t, M
Φ « d M tr TJ Hi cr P; < TJ rr rr Ω rr ri Φ rr rr tr rr fD μ- fD ti μ- μ- Φ Ω CQ fϋ rr rr 3" d tr Φ Q d ii φ d O rr ^ fu r-h rr Ω ti φ rr rr μ- tr Φ ti ri fD ri Hi tr Φ
3 fl) ^ 3- rr a tr ri d Ω Φ Φ μ- fu Φ rr Φ n
Pi Ω d rr φ fD Φ fD Q 3 O Φ CQ 0 Φ O μ- ri Φ rr H1 ≥! P. 3 o
Hi CQ Φ ri Φ Φ 3
the first layer aided by negative pressure in the apertures provided by the vacuum.
49. The method of claim 48 wherein prior to performing step (d2) , locating an aligning and tension applying means (46) in contact with an exposed major surface of the first layer, the aligning and tension applying means defining apertures (48) therethrough whose centers are aligned with centers of the apertures in the first layer, each aperture in the aligning and tension applying means having a cross-section which is larger than the cross-section of the separate one of the plurality of N optical fibers to be threaded therethrough.
50. The method of claim 48 wherein in performing step (e) the bonding material (50) is applied on the first major surface (15) of the primary substrate opposite the first layer and drawn into the apertures in the primary substrate and the first layer by the vacuum.
51. The method of claim 47 further comprising the steps of:
(f) cleaving each of the plurality of N optical fibers parallel to the exposed surface of electroformed foil once the bonding material has cured: and
(g) grinding and polishing the cleaved ends (30a) of the plurality of N optical fiber (a) to the second surface of the primary substrate when the first layer is removed, and (b) to the exposed surface of the first layer (25) when the first layer remains in engagement with the second surface (19) of the primary substrate.
52. The method of claim 47 wherein the relatively thin first layer is an electroformed layer of a metal.
53. The method of claim 47 wherein the relatively thin first layer comprises a metal of a group consisting of stainless steel, nickel cobalt, carbon steel, aluminum, copper, and nickel.
CO to to t H1 μ> cn o LΠ o cπ o LΠ
of the cross-section of each of the first layer apertures being less than the size of the cross -section of each primary substrate aperture;
(c) locating the relatively thin metal first layer on the second surface (19) of the primary substrate with each first layer aperture being within a footprint of one of the primary substrate apertures such that optical fibers inserted through the primary substrate apertures make contact with the first layer apertures, and the cross-sections of the first layer apertures having limited variations that result in spacings between adjacent optical fibers placed in the primary substrate apertures and in contact with the first layer apertures such that the optical fibers are aligned within the preselected tolerance value;
(d) inserting each of the N optical fibers through a separate aperture in the primary substrate and through a separate aperture in the first layer which is within the footprint of the primary substrate aperture; and
(e) applying a bonding material (50) to the plurality of N optical fibers in their associated apertures in the primary substrate so as to attach the N optical fibers to the primary substrate with the optical fibers being aligned to the preselected tolerance value. 57. The method of 56 further comprising the steps of:
(cl) forming a relatively thin second layer (60) defining N apertures (64) therethrough; (c2) locating the relatively thin second layer on the first surface (15) of the primary substrate such that an edge of each aperture therethrough is within a footprint of one of the apertures in the primary substrate and is horizontally located a preselected distance from an edge of one of the apertures through the first layer; and
(dl) inserting each of the optical fibers through a separate one of the apertures in the second
layer in addition to a separate aperture in the primary substrate and through a separate aperture in the first layer.
58. The method of claim 56 wherein the relatively thin second layer is an electroformed layer of a metal .
59. Array apparatus (10) comprising: a relatively thick primary substrate (12) having sufficient structure to support an array of N spaced-apart elements (30) and having first and second opposing surfaces (15, 19) and defining a plurality of N primary substrate apertures (14) which each extend therethrough from the first surface (15) to the second surface (19) with a cross-section of each of the N substrate apertures being greater than a cross-section of an element such that one element can be passed through in each of the N primary substrate apertures; and a relatively thin first layer (20) , which has insufficient structure by itself to support an array of N spaced-apart elements, engaging the second surface of the primary substrate and defining N apertures (24) therethrough with centers of the first layer apertures being aligned to a preselected tolerance value which is that required for the array of elements, the smallest cross-section of each of the first layer apertures being less than the smallest cross-section of each primary substrate apertures, each first layer aperture being within a footprint of one of the primary substrate apertures such that elements inserted through the primary substrate apertures enter the first layer apertures, and the cross-sections of the first layer apertures having limited variations that result in spacings between adjacent elements placed in the primary substrate apertures and entering the first layer apertures being within the preselected tolerance value such that elements are aligned within the preselected tolerance value.
60. The apparatus of claim 59 further comprising: a relatively thin second layer (60) engaging the first surface (15) of the primary substrate and defining N apertures (64) therethrough; the second layer apertures being larger than the first layer apertures and being separated from the first layer apertures by the primary substrate and with the centers thereof being aligned with the centers of the first layer apertures such that elements inserted through the second layer apertures, the primary substrate apertures, and the first layer apertures are positioned essentially perpendicular to a primary axis of the primary substrate.
61. Array apparatus (10) comprising: a relatively thick primary substrate (12) having sufficient structure to support an array of N spaced-apart elements (30) and having first and second opposing surfaces (15, 19) and defining a plurality of N primary substrate apertures (24) which each extend therethrough from the first surface (15) to the second surface (19) with a cross-section of each of the N substrate apertures being greater than a cross-section of an element such that one element can be passed through in each of the N primary substrate apertures; and a relatively thin first layer (20) , which has insufficient structure by itself to support an array of N spaced-apart elements, engaging the second surface (19) of the primary substrate and defining N apertures (24) therethrough with centers of the first layer apertures being aligned to a preselected tolerance value which is that required for the array of elements, the smallest cross-section of each of the first layer apertures being less than the smallest cross-section of each primary substrate apertures and being greater than the cross- section of the element, each first layer aperture being within a footprint of one of the primary substrate apertures such that elements inserted through the primary substrate apertures can pass through the first layer
apertures, and the cross-sections of the first layer apertures having limited variations that result in spacings between the adjacent elements passing through the primary substrate apertures and the first layer apertures being within the preselected tolerance value such that the elements are aligned within the preselected tolerance value.
62. The apparatus of claim 61 further comprising: a relatively thin second layer (60) engaging the first surface (15) of the primary substrate and defining N apertures (64) therethrough; the second layer apertures being essentially the same size as the first layer apertures and being separated from the first layer apertures by the primary substrate and with the centers thereof being aligned with the centers of the first layer apertures such that elements inserted through the second layer apertures, the primary substrate apertures, and the first layer apertures are positioned essentially perpendicular to a primary axis of the primary substrate.
63. A method of forming an array apparatus (10), which supports N spaced-apart elements (30) to a preselected tolerance value, the method comprising the steps of: (a) forming, in a relatively thick primary substrate (12) having sufficient structure to support an array of N spaced-apart elements, N substrate apertures
(14) which each extend therethrough from a first surface
(15) of the primary substrate to a second surface (19) of the primary substrate with a cross-section of each of the
N primary substrate apertures being greater than a cross- section of an element such that one element can be passed through each of the N primary substrate apertures;
(b) forming a relatively thin first layer (20) defining N apertures (24) therethrough with centers of the layer apertures being aligned to the preselected tolerance value which is that required for the array of elements, the size of the cross-section of each of the
layer apertures being less than the size of the cross- section of each primary substrate aperture;
(c) locating the relatively thin first layer on the second surface (19) of the primary substrate with each first layer aperture being within a footprint of one of the primary substrate apertures such that elements inserted through the primary substrate apertures make contact with the first layer apertures, and the cross- sections of the first layer apertures having limited variations that result in spacings between adjacent elements placed in the primary substrate apertures and in contact with the first layer apertures such that the elements are aligned within the preselected tolerance value; (d) inserting each of the N elements through a separate aperture in the primary substrate and through a separate aperture in the first layer which is within the footprint of the primary substrate aperture; and
(e) applying a bonding material (50) to the plurality of N elements in their associated apertures in the primary substrate so as to attach the N elements to the primary substrate with the elements being aligned to the preselected tolerance value.
64. The method of 63 further comprising the steps of:
(cl) forming a relatively thin second layer (60) defining N apertures (64) therethrough;
(c2) locating the relatively thin second layer on the first surface (15) of the primary substrate such that an edge of each aperture therethrough is within a footprint of one of the apertures in the primary substrate and is horizontally located a preselected distance from an edge of one of the apertures through the first layer; and (dl) inserting each of the elements through a separate one of the apertures in the second layer in addition to a separate aperture in the primary substrate and through a separate aperture in the first layer.
65. A method of forming an array apparatus (10), which comprises an array of N spaced-apart elements (30) aligned to a preselected tolerance value, the method comprising the steps of: (a) forming, in a relatively thick primary substrate (12) having sufficient structure to support an array of N spaced-apart elements, N substrate apertures
(14) which each extend therethrough from a first surface
(15) of the primary substrate to a second surface (19) of the primary substrate with a cross-section of each of the
N primary substrate apertures being greater than a cross - section of an element such that the element can be passed through each of the N primary substrate apertures;
(b) electroforming a relatively thin metal first layer (20) defining N apertures (24) therethrough with centers of the first layer apertures being aligned to the preselected tolerance value which is that required for the array of N spaced-apart elements, the size of the cross-section of each of the first layer apertures being less than the size of the cross-section of each primary substrate aperture;
(c) locating the relatively thin metal first layer on the second surface (19) of the primary substrate with each first layer aperture being within a footprint of one of the primary substrate apertures such that elements inserted through the primary substrate apertures make contact with the first layer apertures, and the cross-sections of the first layer apertures having limited variations that result in spacings between adjacent elements placed in the primary substrate apertures and in contact with the first layer apertures such that the elements are aligned within the preselected tolerance value;
(d) inserting each of the N elements through a separate aperture in the primary substrate and through a separate aperture in the first layer which is within the footprint of the primary substrate aperture; and
(e) applying a bonding material (50) to the plurality of N elements in their associated apertures in the primary substrate so as to attach the N elements to the primary substrate with the elements being aligned to the preselected tolerance value.
66. The method of 65 further comprising the steps of:
(cl) forming a relatively thin second layer (60) defining N apertures therethrough; (c2) locating the relatively thin second layer on the first surface (15) of the primary substrate such that an edge of each aperture therethrough is within a footprint of one of the apertures in the primary substrate and is horizontally located a preselected distance from an edge of one of the apertures through the first layer; and
(dl) inserting each of the elements through a separate one of the apertures in the second layer in addition to a separate aperture in the primary substrate and through a separate aperture in the first layer.