Abstract:
A fiber array module fabrication method. The method includes the steps of: (a) preparing a optical fiber ribbon, a solder/binder coated fiber array substrate, and two holder bases, one holder base having longitudinally extended locating grooves; (b) putting the fiber array substrate in between the holder bases and keeping the longitudinally extended grooves of the fiber array substrate in alignment with the longitudinally extended aligning grooves of the holder base and then loading the optical fiber ribbon in the holder bases and keeping the optical fibers of the fiber ribbon in the locating grooves of the holder base and the fixing grooves of the fiber array substrate; (c) heating the solder or radiating the binder to fixedly secure the optical fibers to the fiber array substrate and the fiber array cover plate, and (d) cutting off the optical fibers and removing the finished fiber array module from the holder bases.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a method for fabricating a fiber array module and, more particularly, to an efficient method for fabricating a fiber array module, which is practical for making fiber array modules rapidly. 
     2. Description of Related Art 
     In recent years, optical fibers are intensively used as signal transmission media in optical communication. By matching with the development of high-channel-counts-plane-wave-guides and that of dense-wavelength-DeMux/Mutiplexer-DWDM, the communication through optical fibers can meet the demand for transmitting high-volume-data in high speed in internet communication and broadband communication. In most cases, plane-wave-guides of high channel counts containing at least a fiber array are commonly used or sandwiched between related photoelectric components for transmitting signals between those photoelectric components. A conventional fiber array module generally comprises a fiber array substrate having a plurality of V-grooves for receiving and holding optical fibers and keeping loaded optical fibers in accurate aligned positions. Due to thin thickness, it is difficult to mount and to align optical fibers into the V-grooves of the fiber array substrate. Although various measures are developed and adapted for aligning and mounting optical fibers on the V-grooves of a fiber array substrate, the most commonly employed measure is to load the optical fibers on the V-grooves manually. However, this manual loading method is inaccurate, time-consuming and expensive because more employers and much time are required to load optical fibers in the V-grooves of a fiber array substrate. 
     Therefore, it is desirable to provide a fiber array module fabrication method and apparatus that eliminates the aforesaid drawback. 
     SUMMARY OF THE INVENTION 
     It is the main object of the present invention to provide a method for fabricating a fiber array module to simplify the assembling steps, to locating or positioning the optical fibers on said base block accurately, repeatedly and efficiently, and to save the time for assembling. 
     It is another object of the present invention to provide a fiber array module fabrication apparatus, which enables simplify the assembling steps, to locating or positioning the optical fibers on said base block accurately, repeatedly and efficiently, and to save the time for assembling optical fiber array substrate 
     To achieve these and other objects of the present invention, the method for fabricating a fiber array module comprises the steps of: providing at least one optical fiber ribbon, at least one fiber array substrate having a plurality of fixing grooves, and a device having at least two holder bases with at least one locating groove and aligning grooves, wherein at least one longitudinally extended fixing groove of said fiber array substrate is coated with solders or binders for locating said optical fibers, said locating groove of said holder bases is functioned for locating said optical fiber ribbon, and said aligning grooves is functioned for aligning said optical fibers extended from said ribbon; putting at least one fiber ribbon in said locating groove of said two holder bases, putting said at least one fiber array substrate in between said holder bases, keeping optical fibers of said optical fiber ribbon in the aligning grooves of said holder bases and the fixing grooves of said fiber array substrate; curing said binders or melting said solders through radiation or heat to fasten said optical fibers on said fiber array substrate; and cutting off said optical fibers from said fiber array substrate and then removing fiber array substrate with the secured optical fibers from said two holder bases. 
     According to one embodiment of the present invention, the apparatus for fabricating a fiber array module by combining at least one optical fiber ribbon, a fiber array substrate, and a fiber array cover plate, wherein the surface of said optical fibers of said optical fiber ribbon or the surface of said fiber array substrate is coated with a layer of binders or solders, comprises: at least two holder bases having locating grooves and a plurality of longitudinally extended locating grooves, wherein said locating grooves are adapted for holding said optical fiber ribbon and for sandwiching said fiber array substrate therebetween, said locating grooves are adapted for aligning said optical fibers extended from said optical fiber ribbon with respective grooves of said fiber array substrate; and a heater or a light adapted to cure said binders or to melt said solders to fix said optical fibers of said optical fiber ribbon to said fiber array substrate and said fiber array cover plate. 
     According to another embodiment of the present invention, the apparatus for fabricating a fiber array module by combining at least one optical fiber ribbon, a fiber array substrate, and a fiber array cover plate, wherein the surface of said optical fibers of said optical fiber ribbon or the surface of said fiber array substrate is coated with a layer of binders or solders, comprises: at least two holder bases having locating grooves and a plurality of longitudinally extended aligning grooves, wherein said locating grooves are adapted for holding said optical fiber ribbon and for sandwiching said fiber array substrate therebetween, said aligning grooves are adapted for aligning said optical fibers extended from said optical fiber ribbon with respective fixing grooves of said fiber array substrate; and a heater or a light adapted for curing said binders or to melting said solders to fix or to fasten said optical fibers of said optical fiber ribbon to said fiber array substrate and said fiber array cover plate. 
     Other objects, advantages, and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a schematic drawing showing a fiber array module fabrication apparatus according to the first embodiment of the present invention. 
     FIG. 2 is a schematic drawing showing a fiber array module fabrication apparatus according to the second embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The fiber array cover plate to be used for making a fiber array module may be variously embodied. Preferably, the fiber array cover plates are plates having grooves corresponding to the grooves of the fiber array substrate. During step (B) of the fiber array module fabrication method, the fiber array substrate is put in between the two holder bases, keeping the grooves of the fiber array substrate respectively aimed at or connected to the locating grooves of one holder base, and then the optical fibers of the optical fiber ribbon are respectively arranged in the grooves of the fiber array substrate and the locating grooves of the holder base. Preferably, the optical fibers arc peripherally coated with a layer of solder or binder. When solder is used, it is preferred to be Sn/Au or Sn/Pb. The selected solder can be coated on the surface of the optical fibers, the fiber array substrate and the corresponding fiber array cover plate. The solder is coated on the optical fibers after stripping of the polymer layer of the optical fibers. 
     With reference to FIG. 1, a fiber array module fabrication apparatus  100  in accordance with the first embodiment of the present invention is shown comprising a first holder base  110  having a locating groove, a second holder base  112  having multiple aligning grooves, and a heat source  130 . The holder bases  110  and  112  are adapted to hold a fiber array substrate  300 , for enabling optical fibers  400  to be put in or aimed at grooves in the fiber array substrate  300 . A pivoted cover  114  is respectively provided at the topside of the first holder base  110  and the topside of the second holder base  112 . After positioning of a optical fiber ribbon  420  in the locating groove of the first holder base  110  and arranging of the optical fibers  400  of the optical fiber ribbon  420  in the aligning grooves of the second holder base  112 , the pivoted covers  114  are closed on the holder bases  110  and  112  to hold the optical fiber ribbon  420  in the fiber array substrate  300 . A space is defined between the holder bases  110  and  112  for receiving the fiber array substrate  300 . The heat source  130  provides heat or radiation to melt the applied solders or polymerize the applied binders on the surface of the optical fibers or the surface of the fiber array substrate, thereby causing applied solders or binders to fixedly secure the optical fibers  400  to the,fiber array substrate  300  and the corresponding fiber array cover plate. A cutter assembly  32  is pivoted to the second holder base  112  in the space between the holder bases  110  and  112 , and adapted to cut off optical fibers  400  at the ends of the grooves of the fiber array substrate  300  adjacent the second holder base  112 , separating the optical fibers  400  at the fiber array substrate  300  from the second holder base  112 . According to this embodiment, the grooves in the second holder base  112  are preferably V-grooves arranged in parallel. 
     The fiber array module fabrication method using the fiber array module fabrication apparatus  100  according to the first embodiment of the present invention is outlined hereinafter. At first, the prepared fiber array substrate  300  is put between the holder bases  110  and  112 , keeping the fixing grooves of the fiber array substrate  300  in alignment with the aligning grooves of the second holder base  112 , and then optical fibers  400  are arranged in the aligning grooves of the second holder base  112  and the fixing grooves of the fiber array substrate  300 . Before installation of the optical fibers  400 , the surface of the fiber array substrate  300  (including the fixing grooves of the fiber array substrate  300 ) is coated with a layer of solders or binders. Preferably, the optical fibers  400  are peripherally coated with a layer of solders or binders. After alignment of the fixing grooves of the fiber array substrate  300  with the aligning grooves of the second holder base  112 , the prepared optical fibers  400  are put in the fixing grooves of the fiber array substrate  300  and the aligning grooves of the second holder base  112 . Because the fixing grooves of the fiber array substrate  300  are respectively aligned with the aligning grooves of the second holder base  112 , the optical fibers  400  can be easily and accurately positioned in the grooves of the fiber array substrate  300 . After positioning of the optical fibers  400  in the grooves of the fiber array substrate  300  and the aligning grooves of the second holder base  112 , the fiber array cover plate  410  is closed on the fiber array substrate  300  over the optical fibers  400  in the fiber array substrate  300 , and the pivoted covers  114  are closed to bold down the optical fiber ribbon  420  in the aligning groove of the first holder base  110  and the optical fibers  400  of the optical fiber ribbon  420  in the aligning grooves of the second holder base  112 , and then the heat source  130  is started to heat or radiate the optical fibers  400 , thereby causing the solder or binder to fixedly secure the optical fibers  400  to the fiber array substrate  300  and the fiber array cover plate  410 . At final, the cutter assembly  132  is operated to cut off the optical fibers along the vertical inner sidewall of the second holder base  112 , and then the assembly of the fiber array substrate  300 , the optical fiber ribbon  420  and the fiber array cover plate  410 , i.e., the finished fiber array module is removed from the fiber array module fabrication apparatus  100 . 
     FIG. 2 shows a fiber array module fabrication apparatus according to the second embodiment of the present invention. According to this embodiment, the fiber array module fabrication apparatus  200  comprises two first holder bases  610  each having a longitudinally extended locating groove, a second holder base  612  having a plurality of longitudinally extended aligning grooves, the second holder base  612  being spaced between the first holder bases  610 , two cutter assemblies  632  respectively pivoted to two opposite vertical lateral sides of the second holder base  612 , and two heat sources  630  respectively arranged between the first holder bases  610  and the second holder base  612 . 
     The holder bases  610  and  612  are adapted to hold two fiber array substrates  700 , keeping the fixing grooves of the fiber array substrates  700  respectively aimed at or connected to the aligning grooves of the second holder base  612 , so that optical fibers  400  of optical fiber ribbon s  820  can easily and accurately be put in the fixing grooves of the fiber array substrates  700 . Two covers  614  are respectively pivoted to the first holder bases  610  and adapted to hold down the optical fiber ribbon s  820 . After positioning of optical fiber ribbons  820  in the locating grooves of the first holder bases  610  and arranging of the optical fibers  800  of the optical fiber ribbons  820  in the aligning grooves of the second holder base  612 , the pivoted covers  614  are closed on the first holder bases  610  to hold down the optical fiber ribbons  820  in the fiber array substrates  700 . Two spaces are respectively defined between the first holder bases  610  and the second holder base  612  for receiving the fiber array substrates  700 . The heat sources  130  provide heat or radiation to melt applied solder or polymerize applied binder, thereby causing applied solder or binders to fixedly secure the optical fibers  800  to the fiber array substrates  700  and the corresponding fiber array cover plates. The cutter assemblies  632  are respectively pivoted to the second holder base  612  in the spaces between the first holder bases  610  and second holder base  612 , and adapted to cut off optical fibers  700  at the ends of the grooves of the fiber array substrates  700  adjacent the second holder base  612 , separating the optical fibers  700  at the fiber array substrates  700  from the second holder base  612 . According to this embodiment, the grooves in the second holder base  612  are preferably V-grooves arranged in parallel. 
     The fiber array module fabrication method using the fiber array module fabrication apparatus  200  according to the second embodiment of the present invention is outlined hereinafter. At first, the prepared two fiber array substrates  700  are respectively put in between the first holder bases  610  and the second holder base  612 , keeping the fixing grooves of the fiber array substrates  700  in alignment with the aligning grooves of the second holder base  612 , and then optical fibers  400  are arranged in the locating grooves of the second holder base  612  and the grooves of the fiber array substrates  700 . Before installation of the optical fibers  700 , the surface of each fiber array substrate  700  (including the grooves of each fiber array substrate  700 ) is respectively coated with a layer of solders or binders. Preferably, the optical fibers  700  are peripherally coated with a layer of solders or binders. After alignment of the grooves of the fiber array substrates  700  with the aligning grooves of the second holder base  612 , the prepared optical fibers  800  are put in the fixing grooves of the fiber array substrates  700  and the aligning grooves of the second holder base  612 . Because the fixing grooves of the fiber array substrates  700  are respectively aligned with the aligning grooves of the second holder base  612 , the optical fibers  800  can be easily and accurately positioned in the fixing grooves of the fiber array substrates  700 . After positioning of the optical fibers  800  in the fixing grooves of the fiber array substrates  700  and the aligning grooves of the second holder base  612 , the fiber array cover plates  810  are closed on the fiber array substrates  700  over the optical fibers  800  in the fiber array substrates  700 , and the pivoted covers  614  are closed to hold down the optical fiber ribbons  820  in the locating grooves of the first holder base  610  and the optical fibers  800  of the optical fiber ribbon  820  in the aligning grooves of the second holder base  612 , and then the heat source  630  are started to heat or radiate the optical fibers  800 , thereby causing the solders or binders to fixedly secure the optical fibers  800  to the fiber array substrates  700  and the fiber array cover plates  810 . At final, the cutter assemblies  632  are operated to cut off the optical fibers along the two opposite vertical lateral sidewalls of the second holder base  612 , and then the two assemblies of the respective fiber array substrates  700 , optical fiber ribbon s  820  and fiber array cover plates  810 , i.e., the two finished fiber array modules are removed from the fiber array module fabrication apparatus  200 . 
     Although the present invention has been explained in relation to its preferred embodiments, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed.