Method of fabricating an optical module including a lens...

Details Method of fabricating an optical module including a lens... Method of fabricating an optical module including a lens...

2002-03-25

2004-02-10

Healy, Brian (Department: 2874)

Optical waveguides

With disengagable mechanical connector

Optical fiber to a nonfiber optical device connector

C385S049000, C385S052000, C385S088000, C385S089000, C385S090000, C385S091000, C385S092000

Reexamination Certificate

active

06688783

ABSTRACT:

BACKGROUND OF THE INVENTION
1) Field of the Invention
This invention pertains to the field of optical modules, and more particularly, to a method of fixing a lens in an optical module.
2) Description of the Related Art
FIG. 1
shows an exemplary optical module
100
. The optical module
100
is a so-called “butterfly module,” so named because it has a plurality of electrical leads
105
(e.g., seven) extending from first and second sides
102
,
104
on opposite sides of the optical module
100
, and an output optical fiber
110
extending from a third side
106
generally perpendicular to the first and second sides
102
,
104
. The optical module
100
also includes platform
120
on which is mounted a laser diode
130
which supplies light output to an input aperture
112
of the optical fiber
110
.
A critical characteristic of the optical module
100
is the alignment of the light output of the optical module
100
and the input aperture
112
of the optical fiber
110
. Especially in the case of a single mode fiber, it is critically important that the light output of the laser diode
130
be precisely aligned with the input aperture
112
of the optical fiber
110
.
In the optical module
100
, a lens
140
(sometimes referred to as a micro-lens) focuses the light out of the laser diode
130
onto the input aperture of the optical fiber
110
. It is important that the micro-lens
140
be located in precise alignment with the laser diode
130
the optical fiber
110
. The optical module
100
also includes an optical isolator
180
for preventing light coming back out of the input aperture
112
of the target optical fiber
110
from going back into the laser diode
130
.
However, in the prior art, when attaching the micro-lens
140
to the platform
120
, the micro-lens
140
is subject to significant misalignment with respect to the laser diode
130
and the optical fiber
110
.
Accordingly, it would be advantageous to provide an improved method of fabricating an optical module. In particular, it would be advantageous to provide such a method including an improved method of fixedly attaching a lens to a platform of the optical module such that the lens remains in precise alignment with a light source (e.g., a laser diode) and a target optical fiber even after it is attached or fixed to the platform. Other and further objects and advantages will appear hereinafter.
SUMMARY OF THE INVENTION
The present invention comprises a method for fabricating an optical module, including a method of fixedly attaching a lens to a platform of the optical module such that the lens remains in precise alignment with a light source (e.g., a laser diode) and a target optical fiber even after it is attached to the platform.
In one aspect of the invention, a method is provided for fabricating an optical module including a light source producing light, an optical fiber having an input aperture aligned to receive the light, a ferrule fit around an exterior of the optical fiber, a micro-lens assembly comprising a bridge and a micro-lens holder holding a micro-lens, and a platform. The method comprises holding the optical fiber in place at a desired location with respect to the laser diode; initially aligning the micro-lens to the laser diode to substantially optimize coupling of light into the input aperture of the optical fiber; inserting the bridge beneath the micro-lens holder on the platform; fixing the bridge to the platform; realigning the micro-lens to the laser diode to substantially optimize coupling of light into the input aperture of the optical fiber; and fixing the micro-lens holder to the bridge.


REFERENCES:
patent: 5195155 (1993-03-01), Shimaoka et al.
patent: 5930429 (1999-07-01), Trott
patent: 6207950 (2001-03-01), Verdiell
patent: 6522486 (2003-02-01), Furuhashi et al.
patent: 2003/0026548 (2003-02-01), Bourcier et al.

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