Abstract:
A support assembly for retaining a laser module of the type having a solid state laser, an optical connector and an optical fiber extending between the laser and the optical connector. The support assembly includes a baseplate having a top surface and a bottom surface. A removable spool extends upwardly from the top surface of the baseplate, wherein the spool is sized to have the optical fiber wound therearound. A laser receptacle disposed on the top surface of the baseplate. The laser receptacle is sized to receive the solid state laser in a first predetermined position and orientation. A connector holder is also disposed on the top surface of the baseplate. The connector holder receives and retains the optical connector at a second predetermined position and orientation. As a result, the support assembly retains the solid state laser and the optical connector at known positions that are suitable for automated testing, while the spool retains the optical fiber in a neatly wound condition during the automated testing procedures.

Description:
RELATED APPLICATIONS 
     This application is related to U.S. patent application Ser. No. 09/173,101, filed Oct. 15, 1998, and entitled Spool Support Assembly For The Optical Fiber Of A Laser Module (Potteiger  5 - 1 ), now U.S. Pat. No. 6,007,018 issued Dec. 28, 1999 the disclosure of which is incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to support devices that support electro-optical devices and assemblies during automated manufacturing and testing procedures. More particularly, the present invention relates to support devices that retain a laser source and a segment of optical fiber in an orientation suitable for automated testing on an assembly line. 
     2. Description of the Prior Art 
     There are many different applications that utilize optical fibers. In an optical fiber system, a laser source is typically used to generate a light signal. The light signal is then propagated through an optical fiber that is attached to the laser source. 
     In the telecommunications industry, solid state laser sources are commonly manufactured and sold as part of premanufactured module assemblies. In these modules, a solid state laser is attached to a segment of optical fiber. The optical fiber terminates at its free end with some type of fiber optic connector. In this manner, the laser module can be readily integrated into an existing electro-optical system. An example of such a laser module is the Laser 2000 Module, manufactured and sold by Lucent Technologies of Murray Hill, N.J. 
     There are many different types of premanufactured laser modules currently available. Depending upon the needs of a customer, a premanufactured laser module can be manufactured with a variety of different laser sources, optical fiber types, optical fiber lengths and termination connectors. 
     Regardless of the type of laser module being manufactured, one of the problems commonly encountered in the manufacturing process is that of the handling of the laser module. As has been previously explained, the laser module contains a laser source and a length of optical fiber that extends from that laser source. The length of the optical fiber often can be up to 80 inches. Such a length of optical fiber is difficult to manipulate. The optical fiber can easily tangle and protrude from an assembly in a random direction. As such, laser modules are not readily adapted to automated manufacturing methods because the random position of the optical fiber would makes automated part positioning and testing very difficult. Instead, due to the awkwardness of the optical fibers, laser modules are often handled and tested by hand during manufacture. In such a manner, the optical fiber can be properly oriented as needed. Although such hand manipulated manufacturing and testing procedures are effective, they are highly labor intensive and expensive. 
     A need therefore exists for a laser module handling system that can hold a laser module in a set position during manufacturing and testing, thereby allowing automated manufacturing procedures to be used. 
     SUMMARY OF THE INVENTION 
     The present invention is a support assembly for retaining a laser module of the type having a solid state laser, an optical connector and an optical fiber extending between the laser and the optical connector. The support assembly includes a baseplate having a top surface and a bottom surface. A removable spool extends upwardly from the top surface of the baseplate, wherein the spool is sized to have the optical fiber wound therearound. A laser receptacle is disposed on the top surface of the baseplate. The laser receptacle is sized to receive the solid state laser in a first predetermined position and orientation. A connector holder is also disposed on the top surface of the baseplate. The connector holder receives and retains the optical connector at a second predetermined position and orientation. As a result, the support assembly retains the solid state laser and the optical connector at known positions that are suitable for automated testing, while the spool retains the optical fiber in a neatly wound condition during the automated testing procedures. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a better understanding of the present invention, reference is made to the following description of an exemplary embodiment thereof, considered in conjunction with the accompanying drawings, in which: 
     FIG. 1 is an exploded view of an exemplary embodiment of an assembly in accordance with the present invention; 
     FIG. 2 is a perspective view of the exemplary embodiment of FIG. 1 shown in an assembled condition; 
     FIG. 3 is a perspective view of the bottom of the exemplary embodiment of FIG. 2; and 
     FIG. 4 is a perspective view of the exemplary embodiment of FIG. 2, shown within an automated testing station. 
    
    
     DETAILED DESCRIPTION 
     Although the present invention device and method can be used to hold many different assemblies that have long wire leads or long optical fiber leads, it is particularly useful in the manufacture and assembly of laser modules that have long optical fiber leads. Accordingly, by way of example, the present invention device and method will be described within the context of manufacturing and testing a laser module. 
     Referring to FIG. 1, a prior art laser module  10  is shown. The laser module  10  is a Laser 2000 Module manufactured by Lucent Technologies, the assignee herein. The shown laser module  10  contains a solid state laser  12 . The laser  12  itself has multiple conductive leads  14  that extend outwardly from opposing sides of the solid state laser  12 . The conductive leads  14  are used to both power and control the laser  12  during its operation. The conductive leads  14  are also used to power, control and test the laser  12  during its manufacture. 
     An optical fiber  16  extends from the solid state laser  12 . The optical fiber  16  receives the laser light generated by the solid state laser  12  and propagates that light to its free end. The optical fiber  16  can be of any length. However, in many applications the length of the optical fiber  16  is typically less than 80 inches. The free end of the optical fiber  16  terminates with an optical connector  18 . Many different types of optical connectors  18  can be used depending upon the needs of a customer ordering the laser module  10 . 
     The present invention is an assembly designed to retain the laser module  10  in a set position while the laser module  10  is tested and shipped by the manufacturer. The assembly includes a baseplate  20 , a spool  22  and a connector holder  24 . Each of these elements is fabricated from a static dissipative material to prevent the build-up of electrostatic charge. In the preferred embodiment, the baseplate  20 , spool  22  and connector holder  24  are molded from a conductive plastic. 
     The shown exemplary embodiment of the baseplate  20  is rectangular in shape. Such a shape is merely exemplary and it will be understood that other shapes can be used. A laser test aperture  26  is disposed in one part of the baseplate  20 . Corner supports  28  are formed on opposing sides of the laser test aperture  26 . The corner supports  28  define a laser receptacle  30 , wherein the corner supports  28  receive the corners of the solid state laser  12  and retain the solid state laser  12  in a known fixed position over the laser test aperture  26 . Lead supports  32  are present on the baseplate  20  on opposite sides of the laser test aperture  26 . The lead supports  32  support the conductive leads  14  of the solid state laser  12  when the laser  12  is positioned within the laser receptacle  30  between the corner supports  28 . An illustration of the solid state laser  12  in position over the laser test aperture  26  is shown in FIG.  2 . 
     Still referring to FIG. 1, it can be seen that the connector holder  24  has posts  34  that extend downwardly toward the baseplate  20 . The posts  34  engage corresponding holes  36  that are present in the baseplate  20 . The posts  34  on the connector holder  24  engage the baseplate holes  36  with a slight interference fit, thereby selectively connecting the connector holder  24  to the baseplate  20 . A plurality of different sets of holes can be formed in the baseplate  20 . This allows the connector holder  24  to be positioned at a variety of different positions on the baseplate  20  as desired. It also makes it easy to alter the configuration of the overall assembly as different models of laser modules  10  are received. 
     The connector holder  24  is configured to receive the optical connector  18  being used as part of the laser module  10 . As different optical connectors  18  are used, different connector holders  24  can be substituted on the baseplate  20 . The connector holder  24  shown contains a pawl  37 . The pawl  37  applies a slight bias to the optical connector  18  after the optical connector  18  has been placed within the connector holder  24 . The bias of the pawl  37  helps retain the optical connector  18  in place. 
     The optical fiber  16  that extends from the solid state laser  12  to the optical connector  18  is wound around a spool  22 . The spool  22  contains a cylindrical wall  38  around which the optical fiber  16  is wound. The top of the cylindrical wall  38  terminates with a segmented flange  39  that prevents the wound optical fiber  16  from passing over the top of the cylindrical wall  38 . A cross element  40  spans across the center of the spool  22  in the same general plane as the flange  39 . 
     Locking tabs  42  extend outwardly from the bottom edge of the cylindrical wall  38 . The locking tabs  42  pass through slots  44  in the baseplate  20  and engage the bottom surface of the baseplate  20 , as will later be explained. 
     The baseplate  20  is designed to receive the spool  38 . Two arcuate elements  46 ,  48  extend upwardly from the baseplate  20 . The two arcuate segments  46 ,  48  are arranged as part of a common circle and define a hub structure  50 . The hub structure  50  is sized to fit within the cylindrical wall  38  of the spool  22 . An open area  52  exists between the arcuate segments  46 ,  48  of the hub structure  50 . As will later be explained, the open area  52  allows space for a person&#39;s fingers to engage and turn the cross element  40  of the spool  22  when the spool  22  is engaged with the baseplate  20 . 
     Guide segments  54  are positioned at various points on the baseplate  20  around the hub structure. The guide segments  54  pass around the outside of the spool  22  after the spool  22  is attached to the baseplate  20 . The guide segments  54 , therefore prevent the optical fiber  16  from unwinding from the spool  22  after the spool  22  is attached to the baseplate  20 . 
     Slots  44  are disposed at various points around the two arcuate segments  46 ,  48 . The slots  44  are positioned and shaped to receive the locking tabs  42  on the bottom of the spool  38 . As the spool  22  is attached to the baseplate  20 , the locking tabs  42  pass through the slots  44 . As the spool  38  is rotated, the tabs  42  engage the bottom surface of the baseplate  20 , thereby creating a mechanical connection between the spool  22  and the baseplate  20 . 
     Referring now to FIG. 2, it can be seen that the solid state laser  12  and its conductive leads  14  are held in one set position by the corner supports  28  and lead supports  32  of the baseplate  20 . The optical fiber  16  extending from the solid state laser  12  winds around the spool  22 . The flange  39  at the top of the spool  22  prevents the optical fiber  16  from raising off of the spool  22 . Additionally, the guide elements  54  that surround the spool  22  prevent the optical fiber  16  from unwinding from the spool  22 , to any point beyond the bounds of the baseplate  20 . Optional secondary guidance elements  59  can be provided at various points between the spool  22  and the optical connector  18  to help prevent the optical fiber  16  from protruding beyond the bounds of the baseplate  20 . 
     From FIG. 2, it can also be seen that the cross element  40  of the spool  22  aligns across the open area  52  between the two arcuate segments  46 ,  48  of the hub structure  50  on the baseplate  20 . The open area  52  between the two arcuate segments  46 ,  48  therefore provides room for a person to engage the cross-element  40  with his/her fingers and turn the spool  22 . By turning the spool  22 , a person can cause the spool  22  to either engage or disengage the baseplate  20 . 
     Referring to FIG. 3, it can be seem that various T-slots  63  are formed on the bottom surface  64  of the baseplate  20 . The use of T-slots is merely exemplary and it should be understood that any type of mechanical connection configuration can be used. 
     Referring now to FIG. 4, it can be seen that the baseplate  20  of the assembly is adapted to connect to a metal boat  70 . The metal boat  70  contains T-protrusions that selectively engage the T-slots on the bottom of the baseplate  20 . In the manufacturing procedure, the present invention assembly and metal boat  70  are placed on an automated track  72 . The automated track  72  takes the assembly to an automated testing station. Once in the automated testing station a test socket actuator  74  raises up though the metal boat  70  and the baseplate  20  and contacts the solid state laser  12  through the laser test aperture  26  (FIG. 1) that is present in the baseplate  20 . The test socket actuator  74  lifts the solid state laser  12  out of the laser receptacle  30  defined by the corner supports  28  and biases the conductive leads  14  of the laser  12  against a fixed test head  76 . The test head  76  electrically interconnects with the conductive leads  14 , wherein power and diagnostic test commands can be read to the solid state laser  12 . Guidance holes  78  can optionally be positioned proximate the laser receptacle  30 . The fixed test head  76  may contain guide posts (not shown) that engage the guidance holes  78  thereby ensuring accurate alignment between the solid state laser  12  and the fixed test head  76 . 
     As the solid state laser  12  is interconnected with the fixed test head  76 , the optical connector  18  is positioned next in an optical receiver, via an integrating sphere  79 . As such, the test station can control the inputs to the solid state laser  12  and can monitor the output of the laser module. Accordingly, the entire laser module can be tested at the test station in an automated fashion. When the testing diagnosis is over, the test socket actuator  74  retracts and again lowers the solid state laser  12  into the corner supports  28  on the baseplate  20 . 
     After the laser module has successfully passed testing, the baseplate  20  is removed from both the metal boat  70  and the assembly track  72 . The entire assembly can then be packaged and shipped as a unit. Consequently, the assembly used to retain the laser module during testing can also be used to retain the laser module during shipping. The customer can then remove the laser module from the assembly and recycle the assembly back to the manufacturer. 
     By using a single assembly to retain the laser module during both testing and shipping, the laser module need not be handled. Accordingly, the potential of damage to the laser module is reduced. Simultaneously, the degree of labor and expense needed to package the laser module is reduced. 
     It will be understood that the embodiment of the present invention specifically shown and described is merely exemplary and that a person skilled in the art can make alternate embodiments using different configurations and functionally equivalent components. For example, the shape and position of the various elements on the baseplate can be varied to meet the needs of a specific application. All such alternate embodiments are intended to be included in the scope of this invention as set forth in the following claims.