Patent ID: 7440668
Filing Date: 2008-10-21
Classification: G02B

Abstract:
1. A method for fabricating an optical connector, comprising the steps of: forming a first substrate having a first array of recessed v-groove channels in a first portion of the first substrate and a first recessed cavity in a second portion of the first substrate, wherein each of the recessed v-groove channels of the first array includes an upper portion having substantially vertical sidewalls and a lower portion including converging inclined sidewalls, and wherein the forming of the first array of recessed v-groove channels in the first portion of the first substrate comprising: anisotropically wet etching the surface of the first substrate to form the first array of recessed v-groove channels in the first portion of the first substrate, and dry etching the first substrate to recess the v-groove channels to a desired depth below the surface of the first substrate; forming a second substrate having a second array of v-groove channels in a first portion of the second substrate and a second recessed cavity in a second portion of the second substrate; stripping an end portion of the fiber optic cable to provide a portion of fiber optic cable comprising a buffer polymer layer portion with optical fibers extending therefrom; and mounting the stripped fiber optic cable between the first and second substrates to form a connector, wherein the buffer polymer portion is mounted in the recessed cavities of first and second substrates and the optical fibers extending from the buffer polymer portion are mounted in corresponding v-groove channels of the first and second substrates, and wherein one end of each optical fiber is exposed on a side wall of the connector.