Patent ID: 7108809

Claim:
A method of producing an optical fiber coupler, said method comprising the steps of: applying a layer of epoxy to a first substrate and curing said epoxy; scribing said epoxy layer after said curing step to form cross-wise grooves or cross-wise ridges; applying a metallic coating over the scribed epoxy layer, said metallic coating assuming a shape of said cross-wise grooves or cross-wise ridges; applying a layer of moldable material to a second substrate; positioning said first and second substrates such that said metallic coating faces said layer of moldable material, and pressing said first substrate and said second substrate against each other such that said cross-wise grooves or cross-wise ridges of said epoxy layer and said metallic coating are embossed into said moldable layer; and subsequently separating said first substrate from said second substrate, wherein the moldable layer forms said optical fiber coupler and the cross-wise grooves or cross-wise ridges locate optical fibers.